Page 1
Service Manual
Experience
EFX800-16 Base
™
Series 800 line
®
EFX
Fixed and Moving Arms
Page 2
Contents
1Introduction 1
General Information 3
Orientation 3
Covers and Panels 3
System Component Overview 4
Tools 5
Specification Summary Table 5
Parts 7
Lubricants 7
Cleaning Solutions 7
Electrical Requirements 8
Safety Guidelines 9
Safety guideline you need to know and follow: 9
2Operation Verification 11
Operation Verification Tests 11
Operation Verification Checklist 12
3Standard Service and Diagnostics Menus 13
About 13
Service Access Codes 13
How to Access the Service and Diagnostics Menus 14
P10, P20, and P30 consoles 14
P80 consoles 14
P62 and P82 consoles 15
Navigating the Service Menus 16
P10 & P30 consoles 16
P80 and P82 consoles 16
P62 consoles 17
Hardware Validation Service Menu (51765761) 18
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P10, P20, and P30 consoles 18
P62, P80, and P82 consoles 19
Club Settings Service Menu (5651565) 20
P10 & P30 consoles 20
P62, P80, and P82 Console 22
About menu 22
Equipment Usage menu 23
System Settings menu 24
Maintenance menu 27
Information Display (65) 28
P10, P20, and P30 consoles 29
P62, P80, and P82 consoles 29
4Adjustment Procedures 31
Available Adjustment Procedures 31
First Stage Drive Belt Tension Adjustment 32
About 32
Procedure 33
Second Stage Drive Tension Adjustment 36
About 36
Procedure 37
Lift Motor Calibration 40
About 40
Procedure 40
5Replacement Procedures 43
Available Replacement Procedures 43
Battery Replacement 44
About 44
Determining the battery condition 44
Battery Fuse 44
Covers and Panels Replacement 47
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About 47
Cover Replacement Procedures 49
Front Lift Cover Replacement 49
Lift Interface Plate Cover Replacement 51
Accessory Tray Cover Replacement 53
Ramp-to-Drive Transition Cover Replacement 54
Ramp Cover Replacement 55
Drive Access Cover Replacement 56
Drive Disk Covers Replacement 57
Drive Housing Covers Replacement 59
First Stage Drive Belt Replacement 67
About 67
Procedure 68
Second Stage Drive Belt Replacement 72
About 72
Procedure 73
Generator and Eddy Brake Assembly Replacement 77
About 77
Procedure 77
Step-up Pulley and Tensioner Assembly Replacement 82
About 82
Step-upPulley and Tensioner Assembly Exploded View 83
Procedure 83
Drive Components Assembly Replacement 86
About 86
Procedure 86
Cranks and Input Bearing Assembly Replacement 93
About 93
Procedure 93
Lift Motor Replacement 99
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About 99
Specifications 99
Lift motor power 99
Procedure 99
LPCA (Lower PCA) Board Replacement 105
About 105
LPCA System Block Diagram 105
LPCA Interface Connections 106
LPCAFuse Locations 107
Procedure 108
Fixed Arms Replacement 112
About 112
Procedure 112
Moving Arms Replacement 114
About 114
Procedure 114
Stairarm Replacement 117
About 117
Procedure 117
6Troubleshooting 123
About 123
Introduction To Troubleshooting 123
Basic Steps 123
Standard Error Codes 125
About 125
Viewing Logged Error Codes 126
Available Error Codes 127
Troubleshooting with Error Codes 127
Error Log & Event Log 128
About 128
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Accessing the Error Log & Event Log 128
Using the Error Log & Event Log 129
Error Log & Event Log 131
About 131
Accessing the Error Log & Event Log 131
Using the Error Log & Event Log 132
Active Status Light (ASL) 133
About 133
ASL Overview 134
ASL States 135
ASL Functions 136
System Troubleshooting Procedures 139
Available Troubleshooting Procedures 139
Blown Battery FuseTroubleshooting 140
8Preventive Maintenance 142
About 142
Maintenance Schedule 142
9Theory of Operation 145
About 145
What's New 145
Operating Summary Information 145
Power-up Initialization State 145
Banner Default State 145
System Component Overview 146
System Wiring Diagram 149
10Exploded View Diagram & Parts List 150
About 150
Exploded View Diagrams and Parts LIst 150
Exploded View Diagrams 151
Exploded View Diagram - Fixed ArmModels 152
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Page 2 of 5 153
Page 3 of 5 154
Page 4 of 5 155
Page 5 of 5 156
Exploded View - Moving Arms Option 157
Page 2 of 5 158
Page 3 of 5 159
Page 4 of 5 160
Page 5 of 5 161
Parts LIst 163
Parts List - Fixed Arm Models 163
Parts List - Moving Arm Models 167
Appendix A : Edition Information i
Edition i
Copyright i
Appendix B : Notices and Safety ii
Trademarks ii
Intellectual Property ii
Warranty ii
Safety Instruction ii
Safety Notices ii
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1 I ntroduction
1Introduction
If you are not a Precor certified servicer, you must not attempt to service any Precor Product.
Call your dealer for service.
WARNING: This service documentation is for use by Precor certified servicer pro-
viders only. Personal injury can result from electrical shock and/or mechanicalmoving
parts.
This service manual applies to the Experience™ Series 800 Line EFX®models with the
EFX800-16 Base.
Model EFX800-16 Base Configuration
EFX833 Fixed Arms, Moving CrossRamp, and P30 console
EFX883 Fixed Arms, Moving CrossRamp, with P82 console
EFX835 Moving Arms, Moving CrossRamp, and P30 console
EFX885 Moving Arms, Moving CrossRamp, and P82 console
This document provides information to service the equipment base independent of the
installed console. For console service documentation, refer to the particular console service
manual.
This document contains information required to perform Troubleshooting and replacement procedures required to repair and maintain this equipment including: general product information,
software diagnostic procedures, preventative maintenance procedures, inspection and adjustment procedures, Troubleshooting procedures, replacement procedures and system block
and wiring diagrams.
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1 I ntroduction
Additional Documentation
There is also an online web version if you have internet access at: Online Service Manuall
See Also
"General Information" on the facing page
"Safety Guidelines" on page9
"Operation Verification" on page11
Standard Service Software
"Preventive Maintenance" on page142
"Adjustment Procedures" on page31
"Replacement Procedures" on page43
Troubleshooting
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1 I ntroduction
General Information
General Information
The following information provides general equipment and service information that will help
you to use this manual to properly repair and maintain the elliptical .
Orientation
The equipment orientation (front, right, left, back) used in manual is referenced to a user standing on the equipment facing the console.
Covers and Panels
Covers and Panels
Equipment cover and access panel locations.
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1 I ntroduction
General Information
For cover removal and installation, see "Covers and Panels Replacement" on page47.
System Component Overview
Basic electrical system component locations.
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1 I ntroduction
General Information
Tools
General set of service and repair tools.
l US and Metric Hex Key set l Standard and Phillips screw driver set
l US SAE and Metric Wrench setl DVM Multimeter
l Torque wrench l External Retaining Ring Pliers
l US SAE and Metric socket set l Belt Tension Gauge (recommended Kent-Moore BT-33-73-F)
Specification Summary Table
This table provides a summary of system component torque and belt rating specifications.
System Component Specification
RF coax connector 2.4 in-lbs (0.271 Nm)
Display fasteners 180 in-lbs (20 Nm
Set screws 300 in-lbs (34 Nm)
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1 I ntroduction
General Information
System Component Specification
Plastite screw fasteners 20 in-lbs (2.3 Nm)
Flathead screws 25 in-lbs (2.8 Nm)
Drive Assembly fastener 180 in-lbs (20.3 Nm)
Step-up Pulley and Tension Assy fasteners 180 in-lbs +/- 54 (20.3 +/_ 4.5 Nm)
Generator and Eddy Brake Assy fasteners 180 in-lbs +/- 54 (20.3 +/_ 4.5 Nm)
Linkarm fasteners 300 +/- 90 in-lbs (34 +/- 10 Nm)
Crankarm Retention Plate Fastener 30 +/- 9 in-lbs (3.4 +/- 1 Nm)
Yoke Ramp bolts 320 in-lbs (236.2 Nm)
First Stage Drive Belt Tension - New Belt 140-150 lbs (63.5 - 68 kgs)
First Stage Drive Belt Tension - Used Belt 125 - 135 lbs (56.7 - 61 Kgs)
Second Stage Drive Belt Tension - New Belt 110-120 lbs (50- 54.4 kgs)
Second Stage Drive Belt Tension - Used Belt 92 - 105 lbs (43 - 47.6 kgs)
.
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Parts
IMPORTANT: Always purchase OEM replacement parts and hardware from Precor.
If you use parts not approved by Precor, you could void the Precor Limited Warranty.
Use of parts not approved by Precor may cause injury.
Exploded View Diagram and Parts List
1 I ntroduction
General Information
There is a copy of the parts
Exploded View Diagram
and
Parts Identification List
included in
the "Exploded View Diagram & Parts List" on page150 chapter that you can use as a quick ref-
erence. It is recommended that you go to the servicer partners Precor Connect (or Precor
Connection) website to view the most current parts information including the
Diagram
and
Parts Identification List
l
Precor Connect Partner website
.
Exploded View
Exploded View Diagram and Parts LIst, see "Exploded View Diagram & Parts List" on
page150.
.
Lubricants
Use only synthetic lubricants such as Mobil 1® synthetic or SuperLube® with Teflon® grease.
Use of unapproved lubricants, cleaners, or solvents may void the EFX warranty.
CAUTION: Do not apply any lubricants or wax to the deck and belt. Do not use Wax
Blast, silicon sprays, or other applied lubricants. The use of these lubricants will quickly
degrade the low-friction surface of the deck.
CAUTION: Do not use petroleum based lubricants on mechanical components such
as the lift, as this may result in degradation of nylon gearing mechanisms. Use only synthetic lubricants such as "Super Lube with Teflon" or "Mobile One Synthetic" grease
(RED).
Cleaning Solutions
Wipe down equipment with recommended cleaning solution. Use dry cloth to remove residue
solution.
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1 I ntroduction
General Information
l General:
o
1 oz mild soap (Simple Green) to 30 oz. water.
o
Athletix equipment cleaner, 9x7 pre-saturated wipes (ATHLETIX PRODUCTS).
o
Enivir Safe oxygen enhanced cleaner or Envir Safe glass and multi-task cleaner
concentrate.
l Console and PVS: a diluted solution of one part 91% Isopropyl alcohol to one part
water.
CAUTION: Do not use acidic cleaners and do not spray directly onto the equipment
surfaces.
Electrical Requirements
The EFX is a self-powered unit that does not require external power to operate. Pedaling will
turn an internal generator which generates the power required to supply the internal electronics, lift motor, P10/P30 consoles, and battery charging functions.
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1 I ntroduction
Safety Guidelines
Safety Guidelines
WARNING: Only Precor certified servicers and technicians are permitted to service
Precor products. Personal injury can result from electrical shock and/or mechanical
moving parts.
Safety guideline you need to know and follow:
l Read and follow all Warning notices to protect yourself from personal injury.
l Read and follow all Caution notices to prevent damage to the equipment.
l Read the owner’s manual and follow all operating instructions.
l Operate the equipment on a solid, level surface.
l Visually check the equipment before beginning service or maintenance operations. If it
is not completely assembled or is damaged in anyway, do not attempt to operate the
equipment.
l Never place liquids on any part of the equipment while performing service.
l To prevent electrical shock, keep all electrical components away from water and other
liquids.
l Do not use accessory attachments that are not recommended by the manufacturer.
non-DEM accessories can cause injuries.
l Do not stand or climb on the handlebars, display enclosure or cover.
l On 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.
l On ATM units when the stairarms are in motion; the generator will operate and produce
potentially hazardous voltages even when the battery is disconnected.
l On AMT units 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
l On ATM units, a pinching hazard exists when the unit is operated. It is possible to ser-
iously pinch a finger. The AMT can be mechanically locked by inserting a screwdriver
through the primary sheave and frame.
l On treadmills, removing the hood exposes high voltage components and potentially dan-
gerous machinery. Exercise extreme caution when you perform maintenance procedures with the hood removed.
When servicing the equipment:
l During service operations you will be very close to moving machinery and voltage bear-
ing components:
o
Remove jewelry (especially from ears and neck),
o
Tie up long hair,
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o
Remove neck ties, and
o
Do not wear loose clothing
See Also
"Safety Instruction" on pageii
"Safety Notices" on pageii
1 I ntroduction
Safety Guidelines
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2 O peration Verification
Operation Verification Tests
2Operation Verification
This section provides a method of verifying that the machine is operating correctly and can be
returned to service. Do this operation verification at the end of a maintenance procedure or
whenever it is necessary to ensure that the machine is operating properly.
Operation Verification Tests
Perform this procedure and tests to verify proper operation of the unit (use the "Operation Veri-
fication Checklist" on the next page to track results):
1. Error Code Verification
Verify that there are no current error codes or issues with the unit.
a. Go to the Error Log (or Event Log) to review any logged error codes. Resolve any
relevant active error codes, see"Error Log & Event Log" on page131.
b. P10, P30 consoles: Clear the error log; select a logged error and then hold down
the QUICK START key until the "NO ERRORS" message shows. Repeat process until all error codes are deleted.
TIP: Error Log Delete Short Cut:
Press and hold the PAUSE/RESET key for a minimum of 6 seconds to open the Error
Log and view all logged error codes. If there are no logged error codes, the "Stuck
Key" message will show. To remove error codes, select the error code and press/hold
the QUICK START key until the "NO ERRORS" message shows.
Note:P62, P80, P82 consoles: Error codes are stored in the Event Log (Access
Hardware Validation (5,1,7,6,5,7,6,1) > select Settings > About > Event Log).
Unlike earlier model consoles, the error codes cannot be manually removed.
1. Hardware ValidationTests:
Access the diagnostics Hardware ValidationTests (access code 5,1,7,6,5,7,6,1) and
run the following tests:
a. DISPLAY TEST (select DISPLAY TEST): Follow prompts to run test.
b. KEYPAD TEST (select KEYPAD TEST): Follow prompts to run test.
c. HEART RATE TEST (select HEART RATE TEST): Follow to and run test.
d. CROSSRAMP TEST (select MACHINE TEST > CROSSRAMP TEST ):
i. Use the incline control to verify the incline level 1 and level 20 A/D values,
level 1 = [[[Undefined variable EFX800-16Base.spec-LifMotorAD1]]] and
level 20 = [[[Undefined variable EFX800-16Base.spec-LiftMotorAD20]]].
ii. Use the incline control to set the incline level to 20 and verify the A/D value
is [[[Undefined variable EFX800-16Base.spec-LiftMotorAD20]]].
l Exit: Press the RESET key to exit diagnostics. On P82 consoles, press Back to
exit diagnostic and return to the Home page.
2. Operational Check:
Select the Manual program and operate the elliptical for at least 5 minutes. While
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2 O peration Verification
Operation Verification Checklist
operating the unit, you will verify basic resistance and incline control functionality and
that the various console metric indicators and user interface displays are showing the
correct values and user information:
a. Operate the RESISTANCE control from level 1 through 20. Concentrate on the
feel of the pedaling motion verifying increased resistance. Be on the alert for any
unusual noises, odors, or vibrations.
b. Press and hold the INCLINE UP control to raise the crossramp from level 1 until
the maximum incline level is reached while viewing the incline indicator. Confirm
that the indicators maximum crossramp level reads 20 and that there are no
unusual noises or vibration.
c. Press and hold the INCLINE DOWN control to lower the crossramp from level
20 until the lowest level is reached while viewing the incline indicator. Confirm
that the ramp returns to level 1 (lowest level) and that there are no unusual noises
or vibrations.
3. Final Error Code Check:
Verify that there were no new relevant logged error codes caused the operation verification tests.
a. Go to the Error Log (or Event Log) and make sure that there are no new relevant
logged error codes. If there are any new relevant error codes, resolve the error
code and repeat the operation verification procedure.
b. On P10, P30 consoles, clear the Error Log of all logged error codes.
4. Return to service:
On successful completion of these tests, return unit to service.
Operation Verification Checklist
Use this checklist to track that each "Operation Verification Tests" on the previous page was
successfully completed. When each test was successfully completed, return the unit to service.
Error Log Verification Check, record, and then clear any errors in the error log.
Display Test: Verify the console metric display LEDs function properly.
Keypad Test: Verify console hardkeys and keypad keys function properly.
Heart Rate Test: Verify the heart rate functions properly.
CrossRamp Test; Verify the cross ramp operates through the full incline range.
Operational Check: Verify the unit performance while operating the unit in
Manual program mode.
Error Log Check: Final check for any new error codes that may have been
logged during the verification tests.
.
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3 Standard Service and Diagnostics Menus
About
3Standard Service and Diagnostics Menus
About
There are three Standardized Service and Diagnostics menus used across Precor cardio
product lines providing equipment usage information, club settings, and machine service diagnostic tests:
l Hardware Validation (5,1,7,6,5,7,6,1) is a set of automated diagnostic tests and hard-
ware calibration routines used to troubleshoot and verify machine operation.
l Club Settings (5,6,5,1,5,6,5) also referred to as Club Parameters used to manage and
customize user machine workout limit parameters. On touchscreen consoles, machine
usage information and error event code data is included.
l Information Display (6,5) provides software information, machine usage information,
and error event codes. Only supported on P10, P20, and P30 consoles.
The service and diagnostics menus are accessed by entering the standardized service access
code. The user interface and service menu capabilities will vary based on the console model
and type of exercise equipment. consoles that currently support standardized service modes
include:
Non-touchscreen consoles: P10, P20, and P30
Touchscreen consoles: P62, P80, and P82
Service Access Codes
The following table lists the available standardized service menus and access codes:.
SERVICE
ACCESS CODE SERVICE MENU FUNCTION
5,1,7,6,5,7,6,1 Hardware Validation Diagnostic tests.
5,6,5,1,5,6,5 Club Settings Configure machine and workout
parameter limits
‡
6,5
Information Display View usage stats, HW/SW con-
nectivity, and error code inform-
(2)
ation
.
(1)
.
1) On P62, P80, and P82 consoles, the Information Display (6,5) data is also included in Club Settings (5,6,5,1,5,6,5).
2) The Information Display (65) is not supported on the P62, P80, and P82 consoles, access Club
Setting (5,1,7,6,5,7,6,1) to access similar data.
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3 Standard Service and Diagnostics Menus
How to Access t he Service and Diagnost ics Menus
How to Access the Service and Diagnostics Menus
The process to access the service menus vary between console models. Go to section listed
below for your particular console to learn how to access the service menus.
P10, P20, and P30 consoles
Steps:
1. Press either the STOP, PAUSE, or RESET hardkey an immediately type in the access
code.
P80 consoles
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3 Standard Service and Diagnostics Menus
How to Access t he Service and Diagnost ics Menus
Steps
1. Make sure the P820 is set to the Welcome home page.
2. Press and hold the Pause key while pressing CH up >VOL down > VOL up > CH
down:
3. Use the touch keypad to type in the service access code.
P62 and P82 consoles
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3 Standard Service and Diagnostics Menus
Navigating the Service Menus
Steps
1. Make sure the P82 is set to the Welcome home page.
2. Press and hold the VOL down key while pressing CH up >CH down > CH down > CH
up:
3. Use the touch keypad to type in the service access code.
Navigating the Service Menus
The hardkeys and softkeys used to navigate the service menus vary between console models.
Go to section listed below for your particular console to learn how to navigate the service
menus.
P10 & P30 consoles
The service menus are organized in a sequential top-menu to sub-menu to control item flow
architecture.
Menus and submenus are accessed using a combination of Up/Down arrow, OK, BACK, and
ENTER keys. By design, the arrow keys should be used to scroll from one menu item to the
next, while the OK, ENTER, and BACK keys are used to enter and exit submenus. In some
cases the operation is inconsistent, and the OK/ENTER key will instead advance to the next
menu rather than enter a submenu.
CONSOLE KEY FUNCTION/DESCRIPTION
Up/Down Moves up and down through the current menu.
OK Selects the current menu item or confirms settings.
BACK/CLEAR
PAUSE • Exits service mode
• Returns to the previous menu level without saving changes.
• Hold Back to exit the Display test.
• Press and hold PAUSE for greater than 6 sec will open the Error
Log or show the "Stuck Key" message when there are no logged
errors.
P80 and P82 consoles
:
The P80 and P82 consoles use the touchscreen softkeys to select items and navigate the service diagnostic test menus.
Follow the on-screen prompts run the diagnostic tests.
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3 Standard Service and Diagnostics Menus
P62 consoles
CONSOLE KEY FUNCTION/DESCRIPTION
Softkey controls Use your finger to touch the on-screen softkey controls (OK.
START, STOP, BACK, etc.) or menu item to select.
Scroll Up/Dwn Use your finger to select while swiping your finger Up/Dwn to scroll
through menu items. Some menus provide a scroll bar on the
screen right side to scroll Up/Dwn.
BACK softkey
• Use the touchscreen BACK softkey to return to the previous menu display.
• Continue selecting the BACK softkey to exit the service software.
PAUSE hardkey Stop a running diagnostic test.
P62 consoles
The P62 console uses a combination of touchscreen softkeys and keypad hardkeys to select
and navigate thru the service and diagnostics menus. The P62 uses the BACK hardkey to
return to the previous menu and the PAUSE hardkey to stop a running diagnostic test.
Follow the on-screen prompts run the diagnostic tests.
CONSOLE KEY FUNCTION/DESCRIPTION
Softkey controls Use your finger to touch the on-screen softkey controls (OK. START,
STOP, etc.) or menu item to select.
Scroll Up/Dwn Use your finger to select while swiping your finger Up/Dwn to scroll
through menu lists. Some menus provide an on-screen scroll bar to
scroll Up/Dwn.
BACK hardkey
• On P62 consoles, use the control keypad BACK hardkey to go back
or return to the previous menu display.
• Continue selecting the BACK hardkey to exit the service software.
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3 Standard Service and Diagnostics Menus
Hardware Validation Service Menu (51765761)
CONSOLE KEY FUNCTION/DESCRIPTION
PAUSE hardkey Stop a running diagnostic test.
Hardware Validation Service Menu (51765761)
Access Code: 5,1,7,6,5,7,6,1 (see "Service Access Codes" on page13)
The Hardware Validation menu provides a set of automated diagnostic tests and hardware calibration routines used to troubleshoot, calibrate, and verify machine operation. The diagnostic
tests are customized for the particular equipment type and console configuration.
P10, P20, and P30 consoles
Menu path:Hardware Validation Tests (5,1,7,6,5,7,6,1) > Hardware Validation Tests.
DIAGNOSTIC
TEST
DISPLAY TEST
KEYBOARD TEST
PVS KEY TEST
HEART RATE
Tests the console LEDs. Successively press the OK key to verify each
group of LEDs and verify that all LEDs illuminate. Press Back to exit the
test.
An illuminated LED map of the function keys will be shown. Press each individual key and verify that the corresponding LED extinguishes. Press and
hold BACK to exit the test.
Not used, OEM test.
Tests the unfiltered, filtered, and pulse heart rate. Grasp the grips to test the
hand held heart rate. Use a Polar heart rate simulator to test the wireless
heart rate. Press the BACK button to exit this test.
TEST DESCRIPTION
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3 Standard Service and Diagnostics Menus
Hardware Validation Service Menu (51765761)
DIAGNOSTIC
TEST
ACTIVE STATUS
LIGHT
AS LIGHT
BRIGHTNESS
RPM TEST
CROSSRAMP
TEST
BATTERY TEST
TEST DESCRIPTION
The current ASL1status light state (blue. pulsing blue, yellow, & pulsing yellow).
Sets the ASL light brightness level and ON/OFF state:HIGH. MED, LOW,
and ON/OFF.
(EFX only) Menu path: MACHINE TEST > RPM TEST
The current RPM (revolutions per Minute) value. The SPM (strides per
minute) is equal to 2 X RPM.
Menu path: MACHINE TEST > CROSSRAMP TEST
(EFX, AMT Only)
Allows lift command operation during an active lift error condition (E40, E42,
E45, E46) even if the lift is out of range, jammed, or otherwise disabled due
to an error condition.
CAUTION: DO NOT jam the crossramp while operating in error mode -
There are no software position limit stops in this mode.
Menu path: MACHINE TEST > BATTERY TEST
(EFX 800 only)
Shows the current battery voltage level as " XX.X VDC Y.".,
Where:
XX>X, measured DC battery voltage, nominal 12.6 - 14.6 Vdc.
Y suffix definition: "C": external AC charger is connected, "L" battery is low
(less than 11.5 Vdc), "CL" charger is connected and the battery is low.
P62, P80, and P82 consoles
Menu path:Hardware Validation Tests (5,1,7,6,5,7,6,1) > System Settings > System
Tests.
On P62, P80, and P82 consoles, the diagnostic tests are located in the Hardware Validation
System Tests menu.
SYSTEM TESTS TEST DESCRIPTION
Brake Test If brake is operational, provides the following information:
l PWRB XXX Displays the current power bits.
l VBUS XX Bus Voltage used to drive the brake.
l M-AMPS XX DC current going through brake.
Battery Test (EFX 800 only)
Shows the current battery voltage level as " XX.X VDC Y.".,
Where:
XX>X, measured DC battery voltage, nominal 12.6 - 14.6 Vdc.
1
Active Status Light: Service and maintenance status light.
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3 Standard Service and Diagnostics Menus
Club Set tings Service Menu (5651565)
SYSTEM TESTS TEST DESCRIPTION
Y suffix definition: "C": external AC charger is connected, "L" battery is low
(less than 11.5 Vdc), "CL" charger is connected and the battery is low.
SPM Test (EFX only)
Current SPM "Strides per Minute" value.
CrossRamp Test
USB1Test
Touchscreen
(EFX, AMT only)
Manually run the lift motor to raise/lower the crossramp through full range,
levels 1 to 20.
Provides the lift potentiometer A/D digital value.
List the active USB ports.
Verify touchscreen operation.
Test
Touchscreen Cal-
Calibrates touchscreen finger press operation.
ibration
Backlight Test
RGB Test
Numeric Backlight
Test
Numeric Display
Test
Heart Rate Tests the handlebar unfiltered, filtered, and pulse heart rate. Grasp the grips to
Tests the display backlight performance.
Tests the display color performance.
Tests the LED numeric display backlight brightness level.
Tests the LED numeric display.
test the hand held heart rate. Use a Polar heart rate simulator to test the wireless heart rate. Press the back button to exit this test.
Club Settings Service Menu (5651565)
Club Settings access code: 5,6,5,1,5,6,5 (see "Service Access Codes" on page13)
On non-touchscreen consoles (P10, P20, and P30), Club Settings is used to manage and customize workout limit parameters. On touchscreen consoles (P62, P80, and P82), Club Settings menu provides access to four main submenus: the About menu, the Equipment Usage
menu, the System Settings menu, and the Maintenance menu.
P10 & P30 consoles
The Club Settings menu is used to configure and customize workout parameters.
Menu path: Club Settings (5,1,7,6,5,7,6,1) > DIAGS - CLUB SETTINGS
1
Short for Universal Serial Bus, is an industry standard developed in the mid-1990s that
defines the cables, connectors and communications profocols used in a bus for connection,
communication, and power supply between computers and electronic devices.
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Club Set tings Service Menu (5651565)
CLUB PARAMETER DESCRIPTION
SAFETY CODE
Enabled or disabled. When enabled, a user password (xxxx) is
required o use the machine.
Factory default: disabled.
SELECT LANGUAGE
Sets the default language for all workouts on this machine. Language for single use workouts can also be set by the user from the
workout options.
Default:English
SET UNITS Sets units of measure to US standard or Metric.
Range: U.S, Metric
Default: U.S.
SET MAX WORKOUT
TIME
Sets the maximum allowable user workout time per session.
Range: 1 to 240 min, NO LIMIT
Default: 60 min
SET MAX PAUSE
TIME
Sets how long the equipment remains in a paused banner during
a workout before resetting.
Range: 1 to 120 sec
Default: 120 sec
SET 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. Settable in 1
minute increments.
Range:1 to 5 min
Default: 5 min
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.
Default: none
SET CROSSRAMP Sets the crossramp default X"Home" incline auto-level. The cross-
ramp will drive to the default incline level after 60 sec of non-use.
Range: 0 - 20
Default: 1
WARNING: The crossramp will automatically drive to the
Default incline level after 90 sec of non-use.
HIDDEN PROGRAMS Either enabled or disabled*, the setting allows the unit to access
specialized fitness tests designed for police, fire fighters and the
military.
Default: disabled
MAINT CONFIG (ASL only) Sets the ASL maintenance counter reminder function
ON/OFF (ASL pulsing blue light ON/OFF).
SET CUSTOM
PROGRAM 1/2
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Sets the use of a customized workout program.
Range: ON/OFF
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Club Set tings Service Menu (5651565)
CLUB PARAMETER DESCRIPTION
Default: OFF
Note: The Total Body Workout can only be turned on in this Club
Settings menu.
Note:* not available on all models.
P62, P80, and P82 Console
P62, P80, and P82 consoles
On P62, P80, and P82 consoles, the Club Settings service menu includes four main
submenus:the About submenu, the Equipment Usage submenu, the System Settings submenu and the Maintenance submenu:
l "About menu" below:General information about the machine (serial number, name,
type, location, software versions, internet/Wi-Fi connectivity) and the event and error
codes (Error Log or CPA1Event Log).
l "Equipment Usage menu" on the facing page:Machine workout usage information
(total workout time & distance, last work start/stop times).
l "System Settings menu" on page24: Provides the user defined club configuration and
setup parameters for Connectivity (internet/Wi-Fi), Display settings, TV settings,
Workout Limits settings, and Manage settings (save, import/export system settings).
l "Maintenance menu" on page27: Provides machine ASLstatus and running belt
required maintenance status and reminder information.
About menu
menu: Club Settings (5,6,5,1,5,6,5) > About
Information about the machine hardware, software, and error event codes.
ABOUT MENU DESCRIPTION
CPA Event Log menu: About > CPA Event Log
The CPA Event Log contains all console and base error diagnostic
messages and error codes including network connectivity information, OEM test codes, and maintenance error codes.
.Note: Use the CPA Event Log and not the CPA Event Log to find
the machine maintenance error event codes. The CPA Event Log
only contains maintenance error codes.
CPA Event Log menu: About > CPA Event Log
The CPA Event Log only contains the machine maintenance error
event codes, see "
1
Control Processing Assembly
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Error Troubleshooting Guide
" for error code
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Club Set tings Service Menu (5651565)
ABOUT MENU DESCRIPTION
description and troubleshooting information.
.Note: Use the CPA Event Log and not the CPA Event Log to find
the machine maintenance error event codes.
Console Serial Number
menu: About > Serial Number
User assigned machine name.
Lower Serial Number menu: About > Serial Number
User assigned machine name.
Friendly Name menu: About > Friendly Name
User assigned machine name.
Location menu: About > Location
Facility location code.
Console Serial Number
Release Bundle Version
menu: About > Console Serial Number
Console serial number.
menu: About > Release Bundle Version
Provides console and base software version numbers: CPA Soft-
ware, LPCA1, Qt App, Boot Kernel, File System.
ETag Check Interval menu: About > ETag Check Interval
OEM use only
Heartbeat Interval menu: About > Heartbeat Interval
OEM use only
Wired MAC Address menu: About > Wired MAC Address
Wired LAN MAC address
WI-FI MAC Address menu: About > Wi-Fi MAC Address
Wireless Wi-Fi MAC address
Network Time
Server1
menu: About > Network Time Server1
NTP2server address
Machine Type menu: About > Machine Type
Specifies the detected machine type: TRED, AMT, EFX.
Equipment Usage menu
menu: Club Settings (5,6,5,1,5,6,5) > Equipment Usage
Information about the usage of the machine.
1
Lower PCA board
2
Network Time Protocol (NTP) is a networking protocol for clock synchronization between
computer systems over packet-switched, variable-latency data networks.
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Club Set tings Service Menu (5651565)
EQUIPMENT USAGE
DESCRIPTION
MENU
Cumulative Workout
Distance
Cumulative Workout
Sessions
Last Workout Start
Timestamp
Last Workout End
Timestamp
menu: Equipment Usage > Cumulative Workout Distance
Machine total workout distance.
menu: Equipment Usage > Cumulative Workout Sessions
Machine total number of workout sessions.
menu: Equipment Usage > Last Workout Start Timestamp
The most recent workout start time.
menu: Equipment Usage > Last Workout End Timestamp
The most recent workout end time.
System Settings menu
menu: Club Settings (5,6,5,1,5,6,5) > System Settings
System Settings submenus:
l "Connectivity menu" below:Network configuration and setup parameters.
l "Display menu" on the facing page:GUI interface and optional apps configuration and
setup parameters.
l "TV Settings menu" on the facing pageTV configuration and setup parameters.
l "Workout Limits menu" on page26: Club workout limit configuration and setup para-
meters
l "Manage Settings" on page27:Used to save and restore Connectivity. Display, Media,
and Workout Limits settings.
SYSTEM SETTINGS
DESCRIPTION
MENU
Connectivity menu menu: Club Settings (5,6,5,1,5,6,5) > System Settings > Con-
nectivity
Internet connectivity settings.
»Network Type menu: System Settings > Connectivity> Network Type
Range: Wired, Wi-Fi
Default: Wired
»Configuration menu: System Settings > Connectivity> Network Con-
figuration
Range: Automatic (recommended), Manual
Default: Automatic
Specifies internet connection mode.
»Status menu: System Settings > Connectivity> Network Con-
figuration
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Club Set tings Service Menu (5651565)
SYSTEM SETTINGS
DESCRIPTION
MENU
Range: Connected, Not Connected
Specifies internet connection status.
»IP Address menu: System Settings > Connectivity> Network Con-
figuration
Specifies console internet IP address.
»Preva®Server menu: System Settings > Connectivity> Network Con-
figuration
Specifies Precor Preva server URL (na.preva.com).
Display menu menu: Club Settings (5,6,5,1,5,6,5) > System Settings > Dis-
play
Console default display configuration settings:language, units,
standby delay, .browser and news reader on/off.
»Default Language menu: System Settings > Display > Default Language
Default: English
Specifies the default user interface language.
»Measurement Units menu: System Settings > Display > Measurement Units
Range: US Standard, Metric
Default: US Standard
Specifies the default measurement units.
»Standby Mode
Delay
menu: System Settings > Display > Standby Mode Delay
Range: 5, 10, 15. 30, 60 minutes
Default: 15 minutes
Specifies the idle wait time before entering standby mode.
»Browser menu: System Settings > Display > Browser
Range: ON/OFF
Default: ON
Show (enable) the Browser app.
»News Reader menu: System Settings > Display > News Reader
Range: ON/OFF
Default: ON
Show (enable) the News Reader app.
TV Settings menu menu: Club Settings (5,6,5,1,5,6,5) > System Settings > TV
Settings
Configuration TV settings and channel guide.
»Channel Guide menu: System Settings > TV Settings > Channel Guide
TV channel configuration.
»TV Source menu: System Settings > TV Settings > Channel Guide
Default:Internal Tuner
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Club Set tings Service Menu (5651565)
SYSTEM SETTINGS
DESCRIPTION
MENU
TV input signal source
»TV Source menu: System Settings > TV Settings > TV Source
Default:Internal Tuner
TV input signal source
»Region menu: System Settings > TV Settings > Region
Specifies the TV input signal modulation format for a particular
geographical region.
»Default Channel menu: System Settings > TV Settings > Default Channel
Default: Not set
TV default channel.
»Skip Unnamed
Channel
menu: System Settings > TV Settings > Skip Unnamed Channels
Default:ON
Skips over unnamed channels.
»Extensive Scan menu: System Settings > TV Settings > Extensive Scan
Default:OFF
Searches all available channel sources.
»Closed Captioning menu: System Settings > TV Settings > Closed Captioning
Default:On
Switches close caption feature ON/OFF.
»Export/Import Channels
menu: System Settings > TV Settings > Export/Import Channels
Export/Import channel mapping using a USB .flash drive.
Workout Limits menu menu: Club Settings (5,6,5,1,5,6,5) > System Settings >
Workout Limits
Specify the workout duration and equipment limits for your facil-
ity.
»Maximum Workout
Duration
menu: System Settings > Workout Limits > Maximum
Workout Duration
Range: 1 to 240 min, NO LIMIT
Default: 60 min
Sets the maximum allowable user workout time per session.
»Maximum Pause menu: System Settings > Workout Limits >Maximum Pause
Range: 1 to 300 sec
Default: 30 sec
Sets how long the equipment remains in a paused banner during
a workout before resetting.
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Club Set tings Service Menu (5651565)
SYSTEM SETTINGS
DESCRIPTION
MENU
»Summary Time Out menu: System Settings > Workout Limits >Summary Time
Out
Sets the time to view the Workout Summary data.
Range: 1 to 120 sec
Default: 60 sec
»CrossRamp AutoLevel
(TRM only)
menu: System Settings > Workout Limits >Summary Time
Out
Range: 1 - 20
Default: 1
Sets the ramp default incline level:
»Register Equipment menu: System Settings > Workout Limits >Register Equip-
ment
GUIinterface to register equipment with Precor.Preva Business
Suite "PBS" (requires PBS user name and password, location
code, base serial number, & friendly name of the unit).
Manage Settings menu: System Settings >Manage Settings
Save and restore settings for Connectivity, Display, Media, and
Workout Limits.
(1) Not available on all models.
Maintenance menu
menu: Club Settings (5,6,5,1,5,6,5) > Maintenance
Information about the machine operating status and running belt condition and maintenance.
MAINTENACE MENU DESCRIPTION
Recommended Action
menu
» Operating Condition menu: Maintenance > Recommended Action > Operating
menu: Maintenance > Recommended Action
Range: Good, Inspect
• Good: No maintenance required.
• Inspect:Maintenance action required.
Used to report the running belt/deck operating condition status
and belt rating.
Condition
Range: Good, Inspect
Good: No maintenance required.
Inspect: There is an issue with the running belt/deck that requires
maintenance service or replacement.
» Belt Rating menu: Maintenance > Recommended Action > Belt Rating
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MAINTENACE MENU DESCRIPTION
Range: 10 - 0 (10- New condition, 0 or 1 - Replace running belt)
A belt rating of 0 or 1 will cause a blue pulsing ASL light indicating
that there is a problem with the running belt/deck and is in need of
servicing or replacement.
Information Display (65)
» Next Maintenance
Due
Active Status Light
(ASL) menu
menu: Maintenance > Recommended Action > Next Maintenance Due
Provides machine maintenance status:.
menu: Maintenance > Active Status Light
Indicates the machine operating and maintenance status, see "
Active Status Light (ASL)" on page133.
Blue Solid: Normal operation Indicates that the ASL has not
detected any logged error codes.
Blue Pulsing: Preventative maintenance reminder.
• Treadmills: A belt rating of 0 or 1 will cause a blue pulsing ASL
light indicating that there is a problem with the running belt/deck
and is in need of servicing or replacement.
• ALL : The maintenance counter starts at 1000 hours counting
down to active use hours to 0 indicating preventative maintenance
is due.
Yellow Solid: Indicates an error has occurred, was self-corrected
and the machine can be used. The fault can be cleared.
Yellow Pulsing There is a current non-recoverable fault condition, there is a loss of a major function and the machine id out-ofservice. Machine service is required.
» AS light Brightness menu: Maintenance > Active Status Light > AS Light Bright-
ness
Range: low, medium, bright
Adjust the ASL brightness level.
» Maintenance
Reminder
menu: Maintenance > Active Status Light > Maintenance
Reminder
Range: OFF/ ON (default)
Switch the maintenance reminder function ON or OFF.
Information Display (65)
Service Access Code: 6,5 (see "Service Access Codes" on page13)
The Information Display is only supported on P10, P20, and P30 consoles. On P62, P80, and
P82 consoles, refer to Club Settings for similar information.
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Information Display (65)
The Information Display menu provides information about the machine usage, software, maintenance, and the error event code log.
P10, P20, and P30 consoles
METRIC DESCRIPTION
ODOMETER The total number of accumulated miles on the unit.
This value is stored in the upper PCA in the console so if
the PCA is replaced the accumulated miles would start
again from "0".
HOUR METER The total number of hours that the unit took to accumulate
unit miles.
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".
BELT RATING
(2)
Displays the belt rating from 10 (best) to 0 (worst). Resettable to 10 by holding down QuickStart.
MAINT COUNTER Hours remaining until maintenance is required (initializes
to 250 hrs, approximately 1 month use).
Press/Hold the PAUSE/RESET key to reset the counter.
U-BOOT SW The console Upper Boot software version information.
U-BASE SW The console Upper Base software version information.
METRICS BOARD SW The console Metrics board software version information
L-MAJOR SW The LPCA Major processor software version information.
L-MINOR SW The LPCA Minor processor software version information.
Note: The Minor software versions can only be viewed
while the user is pedaling. If the user isNOT pedaling, then
the software will be displayed as “--------------“.
L-ASL SW The LPCA Active Status Light processor software version
information.
SER NUMBER Displays the model and serial number of the machine. The
base serial number can be set using the WinCSAFE computer software. The factory default is NONE.
USAGE LOG Displays the type of workout programs the users are
accessing most frequently.
"Error Log & Event Log" on
page131
Table of stored error event codes.
TIP: You can quickly access the Error log by holding down
the PAUSE key. Will show the STUCK KEY message
when there are no logged error codes.
(1) Only available on ASL equipped models.
(2) TRM800-14, TRM700-16 models
P62, P80, and P82 consoles
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Information Display (65)
The P62, P80, and P82 consoles do not support the Information Display service menu (6,5).
On P62, P80, and P82 consoles, the Information Display (6,5) type data is located in Club
Settings (5,6,5,1,5,6,5) service menu, see the P62, P80, and P82 console "Club Settings Ser-
vice Menu (5651565)" on page20.
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4 Adjust ment Procedures
Available Adjustment Procedures
4Adjustment Procedures
Adjustment procedures provide you with the step-by-step adjustment instructions to bring systems and components into specification. Perform the adjustment procedures whenever a
trouble symptom points to a particular component and after a major component is removed/replaced.
Available Adjustment Procedures
"First Stage Drive Belt Tension Adjustment" on the next page
"Second Stage Drive Tension Adjustment" on page36
"Lift Motor Calibration" on page40
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4 Adjust ment Procedures
First Stage Drive Belt Tension Adjust ment
First Stage Drive Belt Tension Adjustment
About
This procedure provides instruction to adjust the First Stage Drive Belt tension.
Specifications
System Component Specification
First Stage Belt Drive Tension - New 140-150 lbs (63.5 - 68 kgs)
First Stage Belt Drive Tension - Used 125 - 135 lbs (56.7 - 61 Kgs)
Drive Component Assy Carriage Bolts 110-120 lbs (50- 54.4 kgs)
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4 Adjust ment Procedures
First Stage Drive Belt Tension Adjust ment
Procedure
Review entire procedure before starting.
1. Remove the Drive Access Cover, see "Drive Access Cover Replacement" on page56.
2. Remove the left drive disk cover, see "Drive Disk Covers Replacement" on page57.
3. Place the belt tension gauge onto the First Stage Drive Belt midway between the two
pulleys and measure the tension. If the tension is within specification, belt tension adjustment is not required. If the tension is not within [[[Undefined variable EFX80016Base.spec-BeltTensionFirstStage-12]]] continue with the belt tension adjustment.
4. Use a 1/2" socket to loosen the two Drive Components Assembly fastener nuts (left
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4 Adjust ment Procedures
First Stage Drive Belt Tension Adjust ment
side) enough to allow assembly movement. Do not remove the fastener nuts.
5. Place the belt tension gauge onto the first stage drive belt midway between the two pulleys and measure the tension.
6. Remove the belt tension gauge. Use a 1/2" socket to decrease or increase the belt tension using the First Stage Belt Tensioner. Only make small incremental tension changes
per adjustment.
IMPORTANT: The belt tension gauge must be removed while making tension adjustments or the measurement will be invalid.
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4 Adjust ment Procedures
First Stage Drive Belt Tension Adjust ment
CAUTION:Make sure to that the two Drive Components Assembly fastener nuts
are loosened before adjusting the tensioner. The tensioner hardware can be damaged by over tightening the adjustment bolt.
7. Use the crankarm to move the belt a couple of rotations. Place the belt tension gauge
onto the first stage drive belt midway between the two pulleys and measure the tension.
Verify that the belt tension is within [[[Undefined variable EFX800-16Base.specBeltTensionFirstStage-12]]]. If the tension is not within specification repeat the tension
adjustment procedure.
8. Use a 1/2" socket to tighten the two Drive Components Assembly fasteners (left side),
torque fasteners to [[[Undefined variable EFX800-16Base.spec-DriveAssyBolts]]].
9. Reinstall the left drive disk cover, see "Drive Disk Covers Replacement" on page57.
10. Reinstall the Drive Access Cover, see "Drive Access Cover Replacement" on page56.
11. Verify machine operation and return to service.
See Also
"Second Stage Drive Tension Adjustment" on the next page
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4 Adjust ment Procedures
Second Stage Drive Tension Adjustment
Second Stage Drive Tension Adjustment
About
This procedure provides instruction to adjust the Second Stage Drive Belt tension.
Specifications
System Component Specification
Second Stage Belt Drive Tension - New 110-120 lbs (50- 54.4 kgs)
Second Stage Belt Drive Tension - Used 92 - 105 lbs (43 - 47.6 kgs)
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4 Adjust ment Procedures
Second Stage Drive Tension Adjustment
System Component Specification
Drive Component Assy Carriage Bolts 180 in-lbs (20.3 Nm)
Procedure
Review entire procedure before starting.
1. Remove the drive disk access cover, see "Drive Access Cover Replacement" on
page56.
2. Remove the left drive disk cover, see "Drive Disk Covers Replacement" on page57.
3. Place the belt tension gauge onto the Second Stage Drive Belt midway between the
two pulleys and measure the tension. If the tension is within specification belt tension,
adjustment is not required. If the tension is not within [[[Undefined variable EFX80016Base.spec-BeltTesnsionSecStage-8]]] continue with the belt tension adjustment.
4. Use a 1/2" socket to loosen the two Generator and Eddy Brake Assembly fastener nuts
(left side)enough to allow assembly movement. Do not remove the fastener nuts.
5. Place the belt tension gauge onto the Second Stage Drive Belt midway between the
two pulleys and measure the tension.
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4 Adjust ment Procedures
Second Stage Drive Tension Adjustment
6. Remove the belt tension gauge. Use a 1/2" socket to decrease or increase the belt tension using the Second Stage Belt Tensioner. Only make small incremental tension
changes per adjustment.
IMPORTANT: The belt tension gauge must be removed while making tension adjustments or the measurement will be invalid.
CAUTION:Make sure to that the two Generator and Eddy Brake Assembly fastener
nuts are loosened before adjusting the tensioner. The tensioner hardware can be
damaged by over tightening the adjustment bolt.
7. Use the crankarm to move the belt a couple of rotations. Place the belt tension gauge
onto the Second Stage Drive Belt midway between the two pulleys and measure the
tension. Verify that the belt tension is within [[[Undefined variable EFX80016Base.spec-BeltTesnsionSecStage-8]]]. If the tension is not within specification
repeat the tension adjustment procedure.
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4 Adjust ment Procedures
Second Stage Drive Tension Adjustment
8. Use a 1/2" socket to tighten the two Generator and Eddy Brake Assembly fasteners (left
side), torque fasteners to [[[Undefined variable EFX800-16Base.specDriveAssyBolts]]].
9. Reinstall the left drive disk cover, see "Drive Disk Covers Replacement" on page57.
10. Reinstall the Drive Access Cover, see "Drive Access Cover Replacement" on page56.
11. Verify machine operation and return to service.
See Also
"First Stage Drive Belt Tension Adjustment" on page32
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4 Adjust ment Procedures
Lift Motor Calibration
Lift Motor Calibration
About
This procedure provides instruction to verify and calibrate the Lift Motor and Incline system.
The Lift Motor calibration should be verified anytime the Lift Motor fuse fails or is replaced or
any incline system component is replaced.
Specifications
System Component Specification
Lift Motor Calibration Distance* 9 in
Yoke/Ramp Fasteners 320 in-lbs (236.2 Nm)
Note: * Calibration distance is set at incline level 10.
Procedure
Review entire procedure before starting.
1. Remove the Front Lift cover, Lift Interface Plate cover, and Ramp cover, see "Front Lift
Cover Replacement" on page49, ."Lift Interface Plate Cover Replacement" on
page51, and "Ramp Cover Replacement" on page55.
2. .Access the diagnostic CROSSRAMP TEST (select Pause key > type 51765761 >
select MACHINE TEST > CROSSRAMP TEST) . Set the ramp level to 10 and disconnect the Lift Motor Assembly input power/control cable.
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4 Adjust ment Procedures
Lift Motor Calibration
WARNING:Make sure to disconnect the Lift Motor input power/control cable or it is
possible for the crossramp to automatically lower to level 1 if either the pedals or
arms are moved. This unexpected action could cause personal injury.
1. Measure and verify that the distance from the top of the jackscrew to the top of the yoke
nut is [[[Undefined variable EFX800-16Base.spec-LiftMotorCal]]].
2. If the calibration distance is not to specification (lift motor calibration distance:
[[[Undefined variable EFX800-16Base.spec-LiftMotorCal]]]), continue procedure to
adjust the Lift Motor calibration distance to specification
3. Place a pad over the top of the Front Frame cover to protect the surface during the
adjustment procedure. Place blocking material (hard foam or similar material) between
the underside of the ramp and frame to support and keep the ramp in the raised position.
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4 Adjust ment Procedures
Lift Motor Calibration
4. Use a 9/16" socket to remove the two ramp - ramp fasteners and remove the yoke from
the ramp. Take Note that the ramp will fall when the fasteners are removed. Make sure
the ramp is supported before removing the fasteners. Retain fastener hardware for
installation.
5. Use your hands to rotate the jackscrew to move the Yoke up or down as needed to
adjust the calibration distance. The Yoke installation position may not allow the calibration distance to be exact. So rotate the jackscrew so that the Yoke Nut provides the
closest plus or minus distance to 9 in.
6. Reattach the Yoke to the Ramp using the two fasteners, torque to 320 in-lbs (236.2
Nm).
7. Remove any blocking materials and pad.
8. Reconnect the input power/control cable.
9. Verify the elliptical incline operation through the full range of motion, levels 1 though 20.
Do the CROSSRAMP TEST diagnostic test.
10. Reinstall the Front Lift, Lift Interface Plate, and Ramp covers, see "Front Lift Cover
Replacement" on page49, ."Lift Interface Plate Cover Replacement" on page51 and
"Ramp Cover Replacement" on page55.
11. Verify elliptical operation and return to service.
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5 Replacement Procedures
Available Replacement Procedures
5Replacement Procedures
Replacement procedures provide you with the step-by-step instructions to remove and install
system components.
Available Replacement Procedures
"Battery Replacement" on the next page
"Covers and Panels Replacement" on page47
"First Stage Drive Belt Replacement" on page67
"Second Stage Drive Belt Replacement" on page72
"Generator and Eddy Brake Assembly Replacement" on page77
"Step-up Pulley and Tensioner Assembly Replacement" on page82
"Drive Components Assembly Replacement" on page86
"Cranks and Input Bearing Assembly Replacement" on page93
"Lift Motor Replacement" on page99
"LPCA (Lower PCA) Board Replacement" on page105
"Fixed Arms Replacement" on page112
"Moving Arms Replacement" on page114
"Stairarm Replacement" on page117
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5 Replacement Procedures
Battery Replacement
Battery Replacement
About
This procedure provides instruction to determine the condition of the battery to remove and
install the Battery.
Determining the battery condition
Use the service software Hardware Validation BATTERY TEST to determine the battery condition and voltage, see Hardware Validation Diagnostic Tests (51765761).
BATTERY TEST
Format XX.X VDC YY
where XX.X is the measured battery voltage in VDC (nominal 12.6 - 14.6 Vdc).
VDC:DC volts
Y is the information suffix:
C: external AC charger connected.
L:Battery is low (less than 11.4 volts).
CL: Charger is connected and battery is low.
Battery Fuse
The battery inline fuse holder is part of the battery assembly cable attached to the battery positive terminal. To remove the fuse, twist the buse holder top cap and remove.
Fuse Type:Inline 10 Amp slow blow fuse, .25" diameter
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5 Replacement Procedures
Battery Replacement
Removal Instructions
Review entire procedure before starting.
1. Remove the left drive disk cover, see "Drive Disk Covers Replacement" on page57.
2. Remove the one #2 Phillips screw fastener and LPCA1/Battery Module cover. Retain
fastener hardware for installation.
1
Lower PCA board
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5 Replacement Procedures
Battery Replacement
3. Disconnect the negative battery cable (black terminal) and then the positive battery
cable (red terminal).
4. If installed, cut the zip tie.
5. Remove the battery.
Installation Instructions
1. Reconnect the positive cable to the positive terminal (red) and then the negative battery
cable to the negative terminal.(black).
2. Reinstall the battery.
3. Make sure the positive wire remains securely connected thru the inline fuse to the LPCA
board.
4. Make sure the negative wire remains securely connected to the frame weldment.
5. Reinstall the LPCA/Battery module cover using the one #2 Phillips screw fastener.
6. Reinstall the left drive disk cover, see "Drive Disk Covers Replacement" on page57.
7. Verify machine operation and return to service, see "Operation Verification" on page11.
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Covers and Panels Replacement
Covers and Panels Replacement
About
These procedure provides instruction to remove and install the EFX covers and panels.
Cover Remove/lnstall Procedure
Goose Neck Cover "Front Lift Cover Replacement" on page49
Top Lift Cover "Front Lift Cover Replacement" on page49
Front Lift Cover "Front Lift Cover Replacement" on page49
Lift Interface Plate Cover "Lift Interface Plate Cover Replacement" on
page51
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Covers and Panels Replacement
Cover Remove/lnstall Procedure
Accessory Tray "Accessory Tray Cover Replacement" on page53
lift Interface Plate "Lift Interface Plate Cover Replacement" on
page51
Ramp Cover "Ramp Cover Replacement" on page55
Ramp-to-Drive Transition Cover "Drive Housing Covers Replacement" on page59
Drive Access Cover "Drive Access Cover Replacement" on page56
Drive Disk Covers "Drive Disk Covers Replacement" on page57
Drive Top Covers "Drive Housing Covers Replacement" on page59
Drive Housing Covers "Drive Housing Covers Replacement" on page59
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Cover Replacement Procedures
Front Lift Cover Replacement
Front Lift Cover Replacement
1.
Removing the front lift cover requires first removing the goose neck gasket and
cover , and the top lift cover .
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Goose Neck Gasket
Goose Neck Cover
Top Lift Cover
Lift Cover
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Removal Instructions
2. Use a nylon tipped screwdriver (or similar plastic device) to unsnap the goose neck
cover and gasket from the top of the front lift cover . Carefully insert the nylon
tip of the screwdriver at the front center between the goose neck cover and front lift
cover seam, While inserting the nylon tip apply pressure to unsnap the goose neck
cover and gasket in an upward direction. Remove the goose neck gasket and cover.
CAUTION:Only use plastic tipped screwdrivers (or similar devices) to unsnap the
goose neck cover Metal tipped devices will scratch the surfaces and damage the covers.
3.
Use your fingers to unsnap and lift the top lift cover from the top of the front lift cover
and accessory tray cover tabs.
4.
Use your fingers to unsnap and lift the front lift cover from the side cover tabs to
remove.
Installation Instructions
1.
Position the bottom of the front lift cover onto bottom front of the EFX base and
press into tabs. Then position the top cover onto the side cover tabs and press to lock in
place.
2.
Use your fingers to position the top lift cover onto the accessory tray and front lift
cover .tabs and press to lock in place.
3.
Use your fingers to position the goose neck cover onto the front lift cover tabs
and press to lock in place.
4.
Reinstall the goose neck gasket onto the display mount post and press into position
onto the top of goose neck flange opening.
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Lift Interface Plate Cover Replacement
Lift Interface Plate Cover Replacement
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Goose Neck Gasket
Goose Neck Cover
Top Lift Cover
Front Lift Cover
Lift Interface Plate Cover
Removal Instructions
1.
Remove the goose neck gasket , goose neck cover , top lift cover , and front
lift cover, see "Front Lift Cover Replacement" on page49.
2.
Remove the two #2 Phillips screw fasteners and remove the lift interface plate cover
. Retain fastener hardware for installation.
Installation Instructions
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1.
Reinstall the lift interface plate cover and secure with the two #2 Phillips screw
fasteners.
2.
Reinstall the front lift , top lift cover , goose neck cover , and goose neck gas-
ket cover, see "Front Lift Cover Replacement" on page49.
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Accessory Tray Cover Replacement
Accessory Tray Cover Replacement
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Accessory Tray cover
Removal Instructions
1. Remove the goose neck gasket, goose neck, and top lift covers, see "Front Lift Cover
Replacement" on page49.
2.
Remove the two #2 Phillips fasteners and remove the accessory tray cover . Retain
fastener hardware for installation.
Installation Instructions
1. Reinstall the accessory tray and secure with the #2 Phillips screw fasteners.
2. Reinstall the top lift cover, goose neck cover, and the goose neck gasket, see "Front Lift
Cover Replacement" on page49.
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Ramp-to-Drive Transition Cover Replacement
Ramp-to-Drive Transition Cover Replacement
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Drive Access Cover
Removal Instructions
Remove the ramp-to-drive transition cover by lifting upward to unsnap the mounting clips.
Installation Instructions
Reinstall the ramp-to-drive transition cover by positioning the cover over the ramp and
drive housing covers and pressing down to snap the mounting tabs in place.
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Ramp Cover Replacement
Ramp Cover Replacement
5 Replacement Procedures
Covers and Panels Replacement
Removal Instructions
1. Use a short stub #3 screwdriver to remove the fastener located on the underside front of
the ramp platform. Lift the front of the ramp cover and slide forward to remove from
retaining clips. Retain fastener hardware for installation.
Installation Instructions
1.
Reinstall ramp cover by inserting the rear tabs into the rear ramp platform mounting
clips and then pressing down (and/or using the palm of your hand to lightly strike the top
of the ramp) on the top front of the ramp to snap into the front bracket clip. Verify that the
ramp clips are correctly engaged by grabbing the ramp sides and gently attempting to
move and lift the ramp off the platform.
2.
Secure ramp by reinstalling the #3 Phillips screw fastener and fully tighten.
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Drive Access Cover Replacement
Drive Access Cover Replacement
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Drive Access Cover
Drive Top Cover
Removal Instructions
1. Use a #3 Phillips screwdriver to remove the two fasteners located at the bottom of the
drive access cover . Slide the access panel downward and away from the frame to
remove. Retain fastener hardware for installation.
Installation Instructions
1.
Slide the top of the drive access cover under the lip of the drive top cover and
then pressing the cover into position over the access cover opening.
2. Secure cover with the two # 3 Phillips screw fasteners.
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Drive Disk Covers Replacement
Drive Disk Covers Replacement
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Drive Disk Cover - right
Drive Disk Cover - left
Removal Instructions
Repeat this procedure for both the right and left drive disk covers.
1. Remove the drive access cover, see "Drive Access Cover Replacement" on the pre-
vious page.
2.
Use the crankarm to rotate the drive disk cover ( right, right) to provide access to
the mounting bracket and the #2 Phillips screw fastener (there is an indent in the upper
inside of the drive housing cover). Use a #2 Phillips screwdriver to remove the fastener
(one screw per side). Retain fastener hardware for installation.
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IMPORTANT: Be careful to not allow the screw to drop to the bottom of the drive
housing area while removing. It may be very difficult to retrieve the dropped screw.
3. Press or lightly tap the disk from the inside outward away from the frame to remove.
Installation Instructions
Repeat this procedure for both the right and left drive disk covers.
1.
Position the drive disk cover over the crankarm and press the cover ( right, right)
onto the three latch catch pins located on the input pulley substrate plate.
2. Use the crankarm to rotate the drive disk cover to the drive housing indent (located at
the inside upper right/left side of the frame) to provide access to the mounting bracket.
Use a #2 Phillips screwdriver to secure the two drive disk cover fasteners.
3. Reinstall the drive access cover, see "Drive Access Cover Replacement" on page56.
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Drive Housing Covers Replacement
Drive Housing Covers Replacement
5 Replacement Procedures
Covers and Panels Replacement
ID Description
Drive Top Cover
Drive Housing Cover - Right
Drive Housing Cover - Left
Ramp-to-Drive Transition Cover
Removal Instructions
Repeat this procedure for both the right and left drive housing covers.
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1. Remove the drive access cover, see "Drive Access Cover Replacement" on page56.
2. Remove the left and right drive disk covers, see "Drive Disk Covers Replacement" on
page57.
3. Repeat steps to remove the left and right stairarms from the crankarm spindle:
a. Remove the #2 Phillips screw fastener and slide the Outer Pivot Block cover rear-
ward and away from the frame to remove. Retain fastener hardware for installation.
b. Remove the #3 Phillips Nylok patch Retention Plate fastener and the Crankarm
Retention Plate. Discard the fastener bolt and retain the Crankarm Retention
Plate for installation.
CAUTION:Do not reuse the removed Retention Plate Nylok patch bolt fasten-
ers for installation. Discard the removed bolts and order new bolts for installation.
c. Use external retaining ring pliers to remove the stairarm pivot block retaining ring.
Retain fastener hardware for installation.
d. Remove the stairarm off the crankarm spindle and carefully lay on the ground.
e. Take note of the pivot block inner wave washer and flat washer. Make sure to not
loose these items, they will be required for installation.
4.
Remove the ramp-to-drive transition cover by lifting upward to unsnap the mounting
clips.
5. Remove the drive top cover:
a.
Remove the two top cover #3 Phillips screw fasteners. Retain fastener hardware for installation.
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b. Straddle the rear housing and reach into the underside of the top cover to unsnap
the left and right front clip fasteners. Simultaneously use your thumbs to press
down on the top of the clips while using your forefingers to grab and lift upward on
the bottom of the clips to release. Continue to slide the top cover forward and lift
up to remove.
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1. Use a 5/16" socket to remove the six screw fasteners from the left drive housing cover
. Carefully slide the cover over the crankarm and remove. Retain fastener hardware
for installation.
Note:The left drive housing cover must be removed prior to removing the right cover.
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2. Use a 5/16" socket to remove the four screw fasteners from the right drive housing
cover . Unplug the ASL1light input cable. Carefully slide the cover over the crankarm and remove. Retain fastener hardware for installation.
1
Active Status Light: Service and maintenance status light.
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Installation Instructions
1.
Carefully slide the right drive housing cover over the crankarm. Reconnect the ASL
light input cable. Place the cover into position and use a 5/16" socket to reinstall the four
screw fasteners.
2.
Carefully slide the left drive housing cover over the crankarm. Place the cover into
position and use a 5/16" socket to reinstall the five screw fasteners.
3.
Reinstall the drive top cover . Position the top cover onto the housing and while applying light pressure first insert the top housing clips and then simultaneously inserting the
top cover front tabs into the front housing mounts and inserting the front clips into the
front housing brackets. Make sure the top cover clips are secure and install the two #3
Phillips screw fasteners.
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4.
Reinstall the ramp-to-drive transition cover . Press on cover to securely lock tabs in
place.
5. Reinstall the left and right stairarms.. Repeat procedure for the left and right stairarms.
a. Make sure the pivot block inner flat washer and wave washer are installed in the
order shown on the crankarm spindle (flat washer then wave washer). Then slide
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the stairarm onto the crankarm spindle.
b. Reinstall the pivot block retaining ring.
c. Reinstall the Crankarm Retention Plate and secure with a new Nylok patch
fastener. Torque to [[[Undefined variable Specifications.EFX16-CrankarmRetentionPlate]]].
CAUTION:Do not reuse the removed Retention Plate Nylok patch bolt
fasteners for installation. Discard the removed bolts and order new
bolts for installation.
d. Reinstall the outer Pivot Block cover and secure with the #2 Phillips screw
fastener.
6. Reinstall the left and right drive disk covers, see "Drive Disk Covers Replacement" on
page57.
7. Reinstall the drive access cover, see "Drive Access Cover Replacement" on page56.
8. Verify the machine operation and return to service.
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First Stage Drive Belt Replacement
First Stage Drive Belt Replacement
About
This procedure provides instruction to remove and install the First Stage Drive Belt.
Specifications
System Component Specification
First Stage Belt Drive Tension - New 140-150 lbs (63.5 - 68 kgs)
First Stage Belt Drive Tension - Used 125 - 135 lbs (56.7 - 61 Kgs)
Drive Component Assy Carriage Bolts 180 in-lbs (20.3 Nm)
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First Stage Drive Belt Replacement
Procedure
Review entire procedure before starting.
Removal Instructions
1. Remove the drive access cover, see "Drive Access Cover Replacement" on page56.
2. Remove the right and left drive disk covers, see "Drive Disk Covers Replacement" on
page57.
3. Remove the right Stairarm, see "Stairarm Replacement" on page117.
4. Use a 1/2" socket to loosen the two Drive Components Assembly fastener nuts (left
side)enough to allow movement. Do not remove the fastener nuts.
5. Use a 1/2" socket to loosen first stage belt tension and walk the first stage drive belt off
the pulleys. Remove the first stage drive belt.
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Installation Instructions
1. Install the first stage drive belt by walking the belt onto the Input drive and smaller first
stage drive pulleys. Adjust the First Stage Tensioner enough to hold the tensioner and
belt in place. Rotate the crank and make sure that the belt is properly aligned and
seated in the pulley grooves.
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First Stage Drive Belt Replacement
2. Tension the first stage drive belt to 140-150 lbs (63.5 - 68 kgs), see ."First Stage Drive
Belt Tension Adjustment" on page32 .
3. Verify that the second stage drive belt is within the specified tension 110-120 lbs (50-
54.4 kgs). If not within specification retention the belt, see "Second Stage Drive Tension
Adjustment" on page36.
4. Tighten the two Drive Components Assembly carriage bolt fasteners, torque to 180 inlbs (20.3 Nm).
5. Reinstall the right Stairarm, see "Stairarm Replacement" on page117.
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First Stage Drive Belt Replacement
6. Reinstall the right and left drive disk covers, see "Drive Disk Covers Replacement" on
page57.
7. Reinstall the drive access cover, see "Drive Access Cover Replacement" on page56.
8. Verify machine operation and return to service, see "Operation Verification" on page11.
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5 Replacement Procedures
Second Stage Drive Belt Replacement
Second Stage Drive Belt Replacement
About
This procedure provides instruction to remove and install the Second Stage Drive Belt.
Specifications
System Component Specification
Second Stage Belt Drive Tension 110-120 lbs (50- 54.4 kgs)
Second Stage Belt Drive Tension - Used 92 - 105 lbs (43 - 47.6 kgs)
Drive Component Assy Carriage Bolts 180 in-lbs (20.3 Nm)
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Second Stage Drive Belt Replacement
Procedure
Review entire procedure before starting.
Removal Instructions
1. Remove the drive access cover, see "Drive Access Cover Replacement" on page56.
2. Remove the right and left drive disk covers, see "Drive Disk Covers Replacement" on
page57.
3. Remove the right Stairarm, see "Stairarm Replacement" on page117.
4. Use a 1/2" socket to loosen the two Generator and Eddy Brake Assembly and the two
Drive Components Assembly fastener nuts (left side). Loosen nuts enough to allow
movement but keep the carriage bolt heads inserted into the adjustment slots. Do not
remove the fastener nuts.
5. Use a 1/2" socket to loosen first stage belt tension and walk the first stage drive belt off
the pulleys. Remove the first stage drive belt.
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Second Stage Drive Belt Replacement
6. Use a 1/2" socket to loosen second stage belt tension and walk the second stage drive
belt off the pulleys. Remove the second stage drive belt.
Installation Instructions
1. Install the second stage drive belt by walking the belt onto the Drive Components
Assembly second stage pulleys. Rotate the crank and make sure that the belt is properly aligned and seated on both pulley grooves. Adjust the second stage tensioner
enough to hold the tensioner and belt in place.
2. Install the first stage drive belt by walking the belt onto the input drive and first stage
drive pulleys. Rotate the crank and make sure that the belt is properly aligned and
seated in the pulley grooves. Adjust the first stage tensioner enough to hold the tensioner and belt in place.
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Second Stage Drive Belt Replacement
3. Adjust the first stage drive belt tension to [[[Undefined variable EFX800-16Base.specBeltTensionFirstStage-12]]], see ."First Stage Drive Belt Tension Adjustment" on
page32 .
4. Adjust the second stage drive belt tension to [[[Undefined variable EFX80016Base.spec-BeltTesnsionSecStage-8]]], see "Second Stage Drive Tension Adjust-
ment" on page36.
5. Use a 1/2" socket to tighten the two Generator and Eddy Brake Assembly and the two
Drive Components Assembly fasteners to [[[Undefined variable EFX800-16Base.specStep-upPulleyTensioner]]].
6. Reinstall the right Stairarm, see "Stairarm Replacement" on page117.
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Second Stage Drive Belt Replacement
7. Reinstall the right and left drive disk covers, see "Drive Disk Covers Replacement" on
page57.
8. Reinstall the drive access cover, see "Drive Access Cover Replacement" on page56,
9. Verify machine operation and return to service, see "Operation Verification" on page11.
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Generator and Eddy Brake Assembly Replacement
Generator and Eddy Brake Assembly Replacement
About
This procedure provides instruction to remove and install the Generator and Eddy Brake
assembly.
Procedure
Review entire procedure before starting.
Removal Instructions
1. Remove the Drive Access cover, see "Drive Access Cover Replacement" on page56.
2. Remove the left and right Drive Disk covers, see "Drive Disk Covers Replacement" on
page57.
3. Remove the one #2 Phillips screw fastener and LPCA1/Battery module cover. Disconnect the Generator input cable (J1) and Eddy/Brake load cable (J7) from the LPCA
board. Retain fastener hardware for installation.
1
Lower PCA board
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Generator and Eddy Brake Assembly Replacement
4. Use a 1/2" socket to loosen the two Generator and Eddy Brake Assembly and the two
Drive Components Assembly fastener nuts (left side). Do not remove the fastener nuts.
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Generator and Eddy Brake Assembly Replacement
5. Use a 1/2" socket to loosen the first stage belt tensioner and walk the first stage drive
belt off the pulleys. Rest the belt on the crankarm, it is not necessary to remove the belt
from the unit. Retain belt for installation.
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Generator and Eddy Brake Assembly Replacement
6. Use a 1/2" socket to loosen the second stage belt tensioner and walk the second stage
drive belt off the pulleys. Remove the second stage drive belt. Rest the pulley on the
crankarm, it is not necessary to remove the belt from the unit. Retain belt for installation.
7. Use a 1/2" socket to remove the Generator and Eddy Brake Assembly lower carriage
bolt fastener. Then slide the assembly down and remove the upper carriage bolt.
Remove the Generator and Eddy Brake Assembly. Retain fastener hardware for installation.
TIP: Remove the lower carriage bolt fastener first and then the upper. The upper bolt
cannot be removed while the lower bolt is installed.
Installation Instructions
1. Reinstall the Generator and Eddy Brake Assembly onto the Step-up Pulley and Tensioner bracket.
2. Slide the assembly down and install the upper carriage bolt. Tighten the bolt enough to
keep the carriage bolt heads inserted into the mounting slot but do not fully tighten. Then
slide the assembly upward and install the lower carriage bolt. Tighten the bolt enough to
keep the carriage bolt heads inserted into the mounting slot but do not fully tighten.
TIP: Install the upper carriage bolt fastener first and then the lower. The upper bolt
cannot be installed when the lower bolt is installed.
3. Walk the second stage drive belt onto the second stage pulleys and tension to 110-120
lbs (50- 54.4 kgs), see "Second Stage Drive Tension Adjustment" on page36.
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Generator and Eddy Brake Assembly Replacement
4. Walk the first stage drive belt onto the first stage pulleys and tension the belt to 140-150
lbs (63.5 - 68 kgs), see "First Stage Drive Belt Tension Adjustment" on page32.
5. Fully tighten the two Generator and Eddy Brake Assembly and two Drive Components
Assembly carriage bolt fasteners, torque to 180 in-lbs (20.3 Nm).
6. Reconnect the Generator input cable (J1) and Eddy/Brake load cable (J7) on the LPCA
board. Reinstall the LPCA/Battery module cover and secure with the #2 Phillips screw
fastener.
7. Reinstall the left and right Drive Disk covers, see "Drive Disk Covers Replacement" on
page57.
8. Reinstall the Drive Access cover, see "Drive Access Cover Replacement" on page56.
9. Verify machine operation and return to service, see "Operation Verification" on page11.
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Step-up Pulley and T ensioner Assembly Replacement
Step-up Pulley and Tensioner Assembly Replacement
About
This procedure provides instruction to remove and install the Step-upPulley and Tensioner
Assembly.
The Step-up pulley and Tensioner Assembly contain the step-up pulleys and the first and
second stage drive belt tensioners
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Step-up Pulley and T ensioner Assembly Replacement
Step-upPulley and Tensioner Assembly Exploded View
Procedure
Review entire procedure before starting.
Removal Instructions
1. Remove the Drive Access cover, see "Drive Access Cover Replacement" on page56.
2. Remove the left and right Drive Disk covers, see "Drive Disk Covers Replacement" on
page57.
3. Remove the left and right Stairarms and the Drive Housing covers, see "Drive Housing
Covers Replacement" on page59.
4. Remove the Drive Components Assembly, see "Drive Components Assembly Replace-
ment" on page86.
TIP: The Step-up Pulley and Tensioner mounting hardware (spacers and isolators)
can easily fall out of the mounting holes. Take care to keep track of these components
for installation, see "Step-upPulley and Tensioner Assembly Exploded View" above.
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Step-up Pulley and T ensioner Assembly Replacement
2. Use a 1/2" socket to loosen the second stage belt tension and walk the second stage
drive belt off the pulleys. Remove the second stage drive belt.
3. Use a 1/2" socket to remove the two carriage bolt fasteners to separate the Generator
and Eddy Brake Assembly from the Step-up Pulley and Tensioner Assembly.
Installation Instructions
1. Reassemble the Drive Components Assemblyy. Place the Generator and Eddy Brake
Assembly onto the Step-up Pulley and Tensioner Assembl mounting bracket. Install the
two carriage bolt fasteners. Tighten the bolts enough to keep the carriage bolt heads
inserted into the mounting and belt adjustment slots, but do not fully tighten.
2. Adjust the second stage tensioner to walk the second stage drive belt onto the pulleys.
Tighten the second stage tensioner bolts enough to keep the belt on the pulleys and tensioner hardware in place. Do not over tension the belt.
3. Reinstall the Drive Components Assembly, see "Drive Components Assembly Replace-
ment" on page86.
4. Reinstall the left and right Stairarms and Drive Housing covers, see "Drive Housing
Covers Replacement" on page59.
5. Reinstall the left and right Drive Disk covers, see "Drive Disk Covers Replacement" on
page57.
6. Reinstall the Drive Access cover, see "Drive Access Cover Replacement" on page56.
7. Verify machine operation and return to service, see "Operation Verification" on page11.
.See Also
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Step-up Pulley and T ensioner Assembly Replacement
"Drive Components Assembly Replacement" on the next page
5 Replacement Procedures
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Drive Components Assembly Replacement
Drive Components Assembly Replacement
About
This procedure provides instruction to remove and install the Drive Components Assembly.
The Drive Components assembly consists of the Step-upPulley and Tensioner assembly and
Generator and Eddy Brake assembly.
Procedure
Review entire procedure before starting.
Removal Instructions
1. Remove the Drive Access cover, see "Drive Access Cover Replacement" on page56.
2. Remove the left and right Drive Disk covers, see "Drive Disk Covers Replacement" on
page57.
3. Remove the Stairarms and Drive Housing covers, see "Drive Housing Covers Replace-
ment" on page59.
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4. Remove the one #2 Phillips screw fastener and LPCA1/Battery module cover. Disconnect the Generator input cable (J1) and Eddy/Brake load cable (J7) from the LPCA
board. Retain fastener hardware for installation.
5. Use a 1/2" socket to loosen the two Generator and Eddy Brake Assembly and the two
Drive Components Assembly fastener nuts (left side). Do not remove the fastener nuts.
1
Lower PCA board
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6. Remove the second stage drive belt tension using a 1/2" socket to loosen the second
stage belt tensioner bolt.
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7. Use a 1/2" socket to loosen the first stage belt tensioner and walk the first stage drive
belt off the pulleys. Retain belt for installation.
8. Use a 1/2" socket to remove the first stage tensioner hardware (adjustment bolt,
washer, isolator bushing, and tensioner tug plate). Retain fastener hardware for installation.
9. Use a 1/2" socket to remove the two Drive Components Assembly carriage bolt fasteners. Remove the rear (lower) bolt first and then slide the Drive Components Assembly
downward to create room to remove the forward (upper) bolt. Remove the Drive Components Assembly. Retain fastener hardware for installation.
TIP: The Step-up Pulley and Tensioner mounting hardware (spacers and isolators)
can easily fall out of the mounting holes. Take care to keep track of these components
for installation, see "Step-upPulley and Tensioner Assembly Exploded View" on
page83.
Installation Instructions
1. Prepare the Drive Components Assembly for installation:
a. If the Drive Components Assembly is disassembled, install the Generator and
Eddy Brake Assembly onto the Step-up Pulley andTensioner Assembly using
the two Carriage bolt fasteners.
b. Tighten the carriage bolts enough to keep the carriage bolt heads inserted into
the mounting slot but do not fully tighten.
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c. Walk the second stage drive belt onto the second stage pulleys. Tighten the ten-
sioner enough to hold the tensioner hardware and belt in position. The belt will be
properly tensioned after the Drive Components Assembly is installed.
2. Reinstall the Drive Components Assembly onto the drive weldment mounting bracket.
Make sure that the Step-up Pulley and Tensioner Assembly mounting hardware is correctly installed, see the exploded view above. Install the upper (forward) carriage bolt
first and then the lower (rear) carriage bolt. Tighten the bolts enough to keep the carriage bolt heads inserted into the mounting slot but do not fully tighten.
3. Install the first stage tensioner hardware (adjustment bolt, washer, isolator bushing, and
tensioner tug plate). Tighten the tensioner bolt enough to hold the hardware in place.
4. Adjust the tensioner as necessary to walk the first stage drive belt onto the first stage pulleys. Rotate the crank and make sure that both the first and second stage drive belts are
properly aligned and seated in the pulley grooves. Tighten both tensioner adjustment
bolts enough to hold the tensioner hardware and belts in position.
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5 Replacement Procedures
Drive Components Assembly Replacement
5. Tension the first stage drive belt to 140-150 lbs (63.5 - 68 kgs), see "First Stage Drive
Belt Tension Adjustment" on page32.
6. Tension the second stage drive belt to 110-120 lbs (50- 54.4 kgs), see "Second Stage
Drive Tension Adjustment" on page36.
7. Tighten the two Generator and Eddy Brake Assembly and two Drive Components
Assembly carriage bolt fasteners, torque to 180 in-lbs (20.3 Nm).
8. Reconnect the Generator input cable (J1) and Eddy/Brake load cable (J7) on the LPCA
board. Reinstall the LPCA/Battery module cover and secure with the #2 Phillips screw
fastener.
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5 Replacement Procedures
Drive Components Assembly Replacement
9. Reinstall the left and right Stairarms and Drive Housing covers, see "Drive Housing
Covers Replacement" on page59.
10. Reinstall the left and right Drive Disk covers, see "Drive Disk Covers Replacement" on
page57.
11. Reinstall the Drive Access cover, see "Drive Access Cover Replacement" on page56.
12. Verify machine operation and return to service, see "Operation Verification" on page11.
See Also
"Second Stage Drive Tension Adjustment" on page36
"First Stage Drive Belt Tension Adjustment" on page32
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5 Replacement Procedures
Cranks and Input Bearing Assembly Replacement
Cranks and Input Bearing Assembly Replacement
About
This procedure provides instruction to remove and install the Cranks and Input Bearing
Assembly.
Specifications
System Component Specification
Cranks and Input Bearing Assy Fasten-
ers
Procedure
Review entire procedure before starting.
Removal Instructions
Experience Series 800 Line EFX
300 +/- 90 in-lbs (34 +/- 10 Nm)
93
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