Service Manual Experience Series 800 line EFXEFX800-16 BaseFixed and Moving Arms

Contents1IntroductionGeneral Information3Orientation3Covers and Panels3System Component Overview4Tools5Specification Summary Table5Parts7Lubricants7Cleaning Solutions7Electrical Requirements8Safety GuidelinesSafety guideline you need to know and follow:231Operation Verification9911Operation Verification Tests11Operation Verification Checklist12Standard Service and Diagnostics Menus13About13Service Access Codes13How to Access the Service and Diagnostics Menus14P10, P20, and P30 consoles14P80 consoles14P62 and P82 consoles15Navigating the Service Menus16P10 & P30 consoles16P80 and P82 consoles16P62 consoles17Hardware Validation Service Menu (51765761)18Experience Series 800 Line EFXii

P10, P20, and P30 consoles18P62, P80, and P82 consoles19Club Settings Service Menu (5651565)4P10 & P30 consoles20P62, P80, and P82 Console22About menu22Equipment Usage menu23System Settings menu24Maintenance menu27Information Display (65)28P10, P20, and P30 consoles29P62, P80, and P82 consoles29Adjustment Procedures31Available Adjustment Procedures31First Stage Drive Belt Tension Adjustment32About32Procedure33Second Stage Drive Tension Adjustment36About36Procedure37Lift Motor Calibration52040About40Procedure40Replacement Procedures43Available Replacement Procedures43Battery Replacement44About44Determining the battery condition44Battery Fuse44Covers and Panels ReplacementExperience Series 800 Line EFX47iii

About47Cover Replacement Procedures49Front Lift Cover Replacement49Lift Interface Plate Cover Replacement51Accessory Tray Cover Replacement53Ramp-to-Drive Transition Cover Replacement54Ramp Cover Replacement55Drive Access Cover Replacement56Drive Disk Covers Replacement57Drive Housing Covers Replacement59First Stage Drive Belt Replacement67About67Procedure68Second Stage Drive Belt Replacement72About72Procedure73Generator and Eddy Brake Assembly Replacement77About77Procedure77Step-up Pulley and Tensioner Assembly Replacement82About82Step-up Pulley and Tensioner Assembly Exploded View83Procedure83Drive Components Assembly Replacement86About86Procedure86Cranks and Input Bearing Assembly Replacement93About93Procedure93Lift Motor ReplacementExperience Series 800 Line EFX99iv

About99Specifications99Lift motor power99Procedure99LPCA (Lower PCA) Board ReplacementAbout105LPCA System Block Diagram105LPCA Interface Connections106LPCA Fuse Locations107Procedure108Fixed Arms Replacement112About112Procedure112Moving Arms Replacement114About114Procedure114Stairarm ing123About123Introduction To Troubleshooting123Basic StepsStandard Error Codes123125About125Viewing Logged Error Codes126Available Error Codes127Troubleshooting with Error Codes127Error Log & Event LogAboutExperience Series 800 Line EFX128128v

Accessing the Error Log & Event Log128Using the Error Log & Event Log129Error Log & Event LogAbout131Accessing the Error Log & Event Log131Using the Error Log & Event Log132Active Status Light (ASL)9133ASL Overview134ASL States135ASL Functions136139Available Troubleshooting Procedures139Blown Battery FuseTroubleshooting140Preventive Maintenance142About142Maintenance Schedule142Theory of OperationAboutWhat's New10133AboutSystem Troubleshooting Procedures8131145145145Operating Summary Information145Power-up Initialization State145Banner Default State145System Component Overview146System Wiring Diagram149Exploded View Diagram & Parts List150About150Exploded View Diagrams and Parts LIst150Exploded View Diagrams151Exploded View Diagram - Fixed Arm Models152Experience Series 800 Line EFXvi

Page 2 of 5153Page 3 of 5154Page 4 of 5155Page 5 of 5156Exploded View - Moving Arms Option157Page 2 of 5158Page 3 of 5159Page 4 of 5160Page 5 of 5161Parts LIst163Parts List - Fixed Arm Models163Parts List - Moving Arm Models167Appendix A : Edition InformationiEditioniCopyrightiAppendix B : Notices and SafetyiiTrademarksiiIntellectual PropertyiiWarrantyiiSafety InstructioniiSafety NoticesiiExperience Series 800 Line EFXvii

1 Introduction1IntroductionIf 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 providers only. Personal injury can result from electrical shock and/or mechanical movingparts.This service manual applies to the Experience Series 800 Line EFX models with theEFX800-16 Base.ModelEFX800-16 Base ConfigurationEFX833Fixed Arms, Moving CrossRamp, and P30 consoleEFX883Fixed Arms, Moving CrossRamp, with P82 consoleEFX835Moving Arms, Moving CrossRamp, and P30 consoleEFX885Moving Arms, Moving CrossRamp, and P82 consoleThis document provides information to service the equipment base independent of theinstalled console. For console service documentation, refer to the particular console servicemanual.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 blockand wiring diagrams.Experience Series 800 Line EFX1

1 IntroductionAdditional DocumentationThere is also an online web version if you have internet access at:Online Service ManuallSee Also"General Information" on the facing page"Safety Guidelines" on page 9"Operation Verification" on page 11Standard Service Software"Preventive Maintenance" on page 142"Adjustment Procedures" on page 31"Replacement Procedures" on page 43TroubleshootingExperience Series 800 Line EFX2

1 IntroductionGeneral InformationGeneral InformationThe following information provides general equipment and service information that will helpyou to use this manual to properly repair and maintain the elliptical .OrientationThe equipment orientation (front, right, left, back) used in manual is referenced to a user standing on the equipment facing the console.Covers and PanelsCovers and PanelsEquipment cover and access panel locations.Experience Series 800 Line EFX3

1 IntroductionGeneral InformationFor cover removal and installation, see "Covers and Panels Replacement" on page 47.System Component OverviewBasic electrical system component locations.Experience Series 800 Line EFX4

1 IntroductionGeneral InformationToolsGeneral set of service and repair tools.US and Metric Hex Key set lUS SAE and Metric Wrench setlTorque wrenchlUS SAE and Metric socket set lllllStandard and Phillips screw driver setDVM MultimeterExternal Retaining Ring PliersBelt Tension Gauge (recommended Kent-Moore BT-33-73-F)Specification Summary TableThis table provides a summary of system component torque and belt rating specifications.System ComponentSpecificationRF coax connector2.4 in-lbs (0.271 Nm)Display fasteners180 in-lbs (20 NmSet screws300 in-lbs (34 Nm)Experience Series 800 Line EFX5

1 IntroductionGeneral InformationSystem ComponentSpecificationPlastite screw fasteners20 in-lbs (2.3 Nm)Flathead screws25 in-lbs (2.8 Nm)Drive Assembly fastener180 in-lbs ( 20.3 Nm)Step-up Pulley and Tension Assy fasteners180 in-lbs /- 54 ( 20.3 / 4.5 Nm)Generator and Eddy Brake Assy fasteners180 in-lbs /- 54 ( 20.3 / 4.5 Nm)Linkarm fasteners300 /- 90 in-lbs (34 /- 10 Nm)Crankarm Retention Plate Fastener30 /- 9 in-lbs (3.4 /- 1 Nm)Yoke Ramp bolts320 in-lbs ( 236.2 Nm)First Stage Drive Belt Tension - New Belt140-150 lbs (63.5 - 68 kgs)First Stage Drive Belt Tension - Used Belt125 - 135 lbs (56.7 - 61 Kgs)Second Stage Drive Belt Tension - New Belt110-120 lbs (50- 54.4 kgs)Second Stage Drive Belt Tension - Used Belt92 - 105 lbs (43 - 47.6 kgs).Experience Series 800 Line EFX6

1 IntroductionGeneral InformationPartsIMPORTANT: 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 ListThere is a copy of the parts Exploded View Diagram and Parts Identification List included inthe "Exploded View Diagram & Parts List" on page 150 chapter that you can use as a quick reference. It is recommended that you go to the servicer partnersPrecor Connect (or PrecorConnection) website to view the most current parts information including the Exploded ViewDiagram and Parts Identification List.lPrecor Connect Partner websiteExploded View Diagram and Parts LIst, see "Exploded View Diagram & Parts List" onpage 150.LubricantsUse 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 WaxBlast, silicon sprays, or other applied lubricants. The use of these lubricants will quicklydegrade the low-friction surface of the deck.CAUTION: Do not use petroleum based lubricants on mechanical components suchas 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 SolutionsWipe down equipment with recommended cleaning solution. Use dry cloth to remove residuesolution.Experience Series 800 Line EFX7

1 IntroductionGeneral InformationllGeneral:o1 oz mild soap (Simple Green) to 30 oz. water.oAthletix equipment cleaner, 9x7 pre-saturated wipes (ATHLETIX PRODUCTS).oEnivir Safe oxygen enhanced cleaner or Envir Safe glass and multi-task cleanerconcentrate.Console and PVS: a diluted solution of one part 91% Isopropyl alcohol to one partwater.CAUTION: Do not use acidic cleaners and do not spray directly onto the equipmentsurfaces.Electrical RequirementsThe EFX is a self-powered unit that does not require external power to operate. Pedaling willturn an internal generator which generates the power required to supply the internal electronics, lift motor, P10/P30 consoles, and battery charging functions.Experience Series 800 Line EFX8

1 IntroductionSafety GuidelinesSafety GuidelinesWARNING: Only Precor certified servicers and technicians are permitted to servicePrecor products. Personal injury can result from electrical shock and/or mechanicalmoving parts.Safety guideline you need to know and follow:lRead and follow all Warning notices to protect yourself from personal injury.lRead and follow all Caution notices to prevent damage to the equipment.lRead the owner’s manual and follow all operating instructions.lOperate the equipment on a solid, level surface.llllllllllVisually check the equipment before beginning service or maintenance operations. If itis not completely assembled or is damaged in anyway, do not attempt to operate theequipment.Never place liquids on any part of the equipment while performing service.To prevent electrical shock, keep all electrical components away from water and otherliquids.Do not use accessory attachments that are not recommended by the manufacturer.non-DEM accessories can cause injuries.Do not stand or climb on the handlebars, display enclosure or cover.On a self-powered unit, it will either be necessary to either equip the unit with theoptional external power supply or have an assistant pedal on the unit while voltagemeasurements are being taken. Because of the danger of working on the unit while it isin motion using the optional external power supply is strongly recommended.On ATM units when the stairarms are in motion; the generator will operate and producepotentially hazardous voltages even when the battery is disconnected.On AMT units with Cardio Theater PVS units will have external power supply andcoaxial cable routed through the bottom of the unit to the top of the display console.Cord management must be maintainedOn ATM units, 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 screwdriverthrough the primary sheave and frame.On treadmills, removing the hood exposes high voltage components and potentially dangerous machinery. Exercise extreme caution when you perform maintenance procedures with the hood removed.When servicing the equipment:lDuring service operations you will be very close to moving machinery and voltage bearing components:oRemove jewelry (especially from ears and neck),oTie up long hair,Experience Series 800 Line EFX9

1 IntroductionSafety GuidelinesoRemove neck ties, andoDo not wear loose clothingSee Also"Safety Instruction" on page ii"Safety Notices" on page iiExperience Series 800 Line EFX10

2 Operation VerificationOperation Verification Tests2Operation VerificationThis section provides a method of verifying that the machine is operating correctly and can bereturned to service. Do this operation verification at the end of a maintenance procedure orwhenever it is necessary to ensure that the machine is operating properly.Operation Verification TestsPerform this procedure and tests to verify proper operation of the unit (use the "Operation Verification Checklist" on the next page to track results):1. Error Code VerificationVerify 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 anyrelevant active error codes, see"Error Log & Event Log" on page 131.b. P10, P30 consoles: Clear the error log; select a logged error and then hold downthe 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 ErrorLog and view all logged error codes. If there are no logged error codes, the "StuckKey" message will show. To remove error codes, select the error code and press/holdthe QUICK START key until the "NO ERRORS" message shows.Note: P62, P80, P82 consoles: Error codes are stored in the Event Log (AccessHardware 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 Validation Tests:Access the diagnostics Hardware Validation Tests (access code 5,1,7,6,5,7,6,1) andrun 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]]] andlevel 20 [[[Undefined variable EFX800-16Base.spec-LiftMotorAD20]]].ii. Use the incline control to set the incline level to 20 and verify the A/D valueis [[[Undefined variable EFX800-16Base.spec-LiftMotorAD20]]].lExit: Press the RESET key to exit diagnostics. On P82 consoles, press Back toexit diagnostic and return to the Home page.2. Operational Check:Select the Manual program and operate the elliptical for at least 5 minutes. WhileExperience Series 800 Line EFX11

2 Operation VerificationOperation Verification Checklistoperating the unit, you will verify basic resistance and incline control functionality andthat the various console metric indicators and user interface displays are showing thecorrect values and user information:a. Operate the RESISTANCE control from level 1 through 20. Concentrate on thefeel of the pedaling motion verifying increased resistance. Be on the alert for anyunusual noises, odors, or vibrations.b. Press and hold the INCLINE UP control to raise the crossramp from level 1 untilthe maximum incline level is reached while viewing the incline indicator. Confirmthat the indicators maximum crossramp level reads 20 and that there are nounusual noises or vibration.c. Press and hold the INCLINE DOWN control to lower the crossramp from level20 until the lowest level is reached while viewing the incline indicator. Confirmthat the ramp returns to level 1 (lowest level) and that there are no unusual noisesor 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 relevantlogged error codes. If there are any new relevant error codes, resolve the errorcode 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 ChecklistUse this checklist to track that each "Operation Verification Tests" on the previous page wassuccessfully 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 inManual program mode.Error Log Check: Final check for any new error codes that may have beenlogged during the verification tests.Experience Series 800 Line EFX12

3 Standard Service and Diagnostics MenusAbout3Standard Service and Diagnostics MenusAboutThere are three Standardized Service and Diagnostics menus used across Precor cardioproduct lines providing equipment usage information, club settings, and machine service diagnostic tests:lllHardware Validation (5,1,7,6,5,7,6,1) is a set of automated diagnostic tests and hardware calibration routines used to troubleshoot and verify machine operation.Club Settings (5,6,5,1,5,6,5) also referred to as Club Parameters used to manage andcustomize user machine workout limit parameters. On touchscreen consoles, machineusage information and error event code data is included.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 accesscode. The user interface and service menu capabilities will vary based on the console modeland type of exercise equipment. consoles that currently support standardized service modesinclude:Non-touchscreen consoles: P10, P20, and P30Touchscreen consoles:P62, P80, and P82Service Access CodesThe following table lists the available standardized service menus and access codes:.SERVICEACCESS CODESERVICE MENUFUNCTION5,1,7,6,5,7,6,1Hardware ValidationDiagnostic tests.5,6,5,1,5,6,5Club SettingsConfigure machine and workoutparameter limits(1).6,5 ‡Information DisplayView usage stats, HW/SW connectivity, and error code information(2).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 ClubSetting (5,1,7,6,5,7,6,1) to access similar data.Experience Series 800 Line EFX13

3 Standard Service and Diagnostics MenusHow to Access the Service and Diagnostics MenusHow to Access the Service and Diagnostics MenusThe process to access the service menus vary between console models. Go to section listedbelow for your particular console to learn how to access the service menus.P10, P20, and P30 consolesSteps:1. Press either the STOP, PAUSE, or RESET hardkey an immediately type in the accesscode.P80 consolesExperience Series 800 Line EFX14

3 Standard Service and Diagnostics MenusHow to Access the Service and Diagn