Precor AMT12 base Service Manual Download Page 204

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Page 204

Gas Shock Removal

5 Release tension from the top of the gas shock by pushing a # 1 flat top screw driver in the slot under

the tension clip. Do not completely remove the retaining clip as it is difficult to reinstall.

Tip: If the incline motor is jammed at full elevation, remove the lower retaining clip to facilitate the gas shock
removal.

6 Using another flat head screw driver as a pry bar, place the screw driver head between the frame and

the top of the gas shock and pry the shock off the upper mounting stud.

7 Rotate the gas shock down and out of the way of the incline motor.

FIGURE 195: GAS SHOCK

Summary of Contents for AMT12 base

Page 1: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 1 Service Manual AMT12 Base Open Stride and Fixed Stride ...

Page 2: ... Guidelines 8 Operating Safety 9 2 Operation Verification 11 Verification Procedure 11 Verification Checklist 12 3 Standardized Service Access Codes 13 Accessing the Service Software 13 P20 Service Software Access 14 Entering the Service Software on a P80 console 15 Hardware Validation Diagnostic Tests 51765761 16 Club Parameter Settings 5651565 17 Information Display 65 18 4 Theory of Operation 1...

Page 3: ...y Law Page 3 Lower Electronics Module 22 DC Power Distribution 22 A regulated 14 5VDC power supply charges the 12V battery 22 AMT Resistance Control 23 Vertical Resistance 23 Horizontal Resistance 24 AMT motion detection RPM 24 DC Lift System Position Monitoring If Equipped 27 ...

Page 4: ...rrors 37 Error 12 Watchdog Lower PCA 37 Error 80 81 82 83 P30 Machine Controls Not Working 38 Troubleshooting the Brake System 39 Troubleshooting the Lift System 40 Error 40 No Lift Motion Detected 41 Error 42 Lift Position Value Out of Range 43 Error 44 Un commanded Lift Motion 45 Error 45 Lift Moving in Wrong Direction 46 Error 46 Low Battery Voltage Open Stride AMT12 only 47 Troubleshooting Com...

Page 5: ...er 4 3 2013 122 Replacing the Lower Board 163 Replacing the Lower PCA and Battery Bracket 164 Replacing the Battery 166 Replacing the Generator Belt 167 Replacing the Generator 169 Replacing the Drive Input Pulley Belt 171 Replacing the Step Up Pulley 172 Replacing the Crank Arm 175 Replacing the Drive Input Pulley 178 Replacing the Lift Arm Housing 185 Replacing the drive input housing 202 Replac...

Page 6: ...n 252 Inspecting and Adjusting the Generator Belt Tension 255 Inspecting and Adjusting the Drive Input Belt Tension 257 Calibrating the Incline Motor 263 Drive Belt Gauge Instructions 265 8 Preventative Maintenance 267 9 Wiring Block Diagrams 269 P30 AMT 11 835 Block Diagram 269 P20_P30_P80 AMT 11 Wiring Diagram 269 10 Exploded View 271 ...

Page 7: ...ice providers only If you are not a Precor Trained Servicer you must not attempt to service any Precor Product Call your dealer for service This document contains information required to perform the majority of troubleshooting and replacement procedures required to repair and maintain this product This document contains general product information software diagnostic procedures when available prev...

Page 8: ...al battery Lastly one of the generators three phase output windings is monitored to determine when the unit is in use and when it is idle This system also determines the step rate by determining the operating speed output frequency of the monitored generator winding A magnetic brake applies resistance to horizontal motion and a sensor that measures horizontal motion stride length General Informati...

Page 9: ...all outlet and the red positive wire must be disconnected from the battery Always ensure that the AMT external power supply is unplugged from the wall outlet and the red positive wire is removed from the battery when you inspect or adjust the AMT or when you isolate remove or replace an AMT component Removing the covers exposes high voltage components and potentially dangerous machinery Exercise e...

Page 10: ...t wear loose clothing Do not wear shoes with heels or leather soles Check the soles of your shoes and remove any embedded stones Tie long hair back Do not rock the unit Do not stand or climb on the handlebars display enclosure or cover Do not set anything on the handlebars display enclosure or cover Never place liquids on any part of the AMT while performing service To prevent electrical shock kee...

Page 11: ...tance is smooth and is controlled from resistance level 1 to resistance level 20 Lift if applicable goes up and down and the A D value changes smoothly throughout the range Press the reset or back key to exit diagnostics 4 Operate the AMT in the Manual program Adjust the resistance to level 7 Operate the AMT for at least 1 minute while pedaling the unit a Concentrate on the feel of the motion and ...

Page 12: ...ardware Validation Tests Heart rate functions normally and displays a valid heart rate Input drive system functions properly throughout the minimum to maximum resistance range All drive system components belts pulleys lower control module free of excessive noise vibrations or smells Incline if equipped A D value increments and decrements smoothly throughout the incline range Incline operates withi...

Page 13: ...ccessing the Service Software Accessing these 3 areas are accomplished the same on all consoles Standard P10 P20 P30 except P80 You must first press either STOP PAUSE or RESET key whichever is available on your specific console followed by a numeric code for the area of service software you wish to access The standard access codes use sequential key presses not simultaneous key hold downs The allo...

Page 14: ...tandard P10 and P30 consoles these codes are entered via a direct access 10 key pad The P20 has a slightly more challenging method of entry P20 Service Software Access The P20 will start with stop pause or reset numeric values have been assigned to the function keys in the absence of the 10 key pad ...

Page 15: ...se or single press version 1 1 or after software release in sequential order an X configuration on the Volume and Channel key pad Channel Up Volume Down Volume Up Channel Down See Diagram 8 Release the Pause button when done pressing the arrows Note The keypad X configuration sequence should not be faster than 1 second between each key stroke Any speed faster than 1 second may result in an unsucce...

Page 16: ...on will be displayed Use this test to determine resistance related problems Press the back button to exit this test RPM Test Base Function Test Pulse is displayed showing a count of zero crossings from the generator RPM shows a software averaged version of Pulse and is displayed in user mode as stride count Use this test to determine stride count related problems Press the back button to exit this...

Page 17: ...ic Factory default is US standard Set Max Workout Time Sets the maximum allowable workout time for each user Factory default is 60 minutes Set Max Pause Time Sets the maximum time that the workout can be paused for Factory default is 120 seconds Set Max Cool Down Time Sets the amount of time that a cool down period will occur at the end of every workout Factory default is 5 minutes Set Metrics Def...

Page 18: ...e upper PCA in the console so if that PCA is replaced the hours of use would start again from 0 Upper Boot Software Displays the current version of software that handles flash upgrades of upper PCA console software Upper Base Software Displays the current version of operating software loaded in the upper PCA console This is the unit specific console software Lower Software Displays the current ver...

Page 19: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 19 4 Theory of Operation Console Models Consoles that could appear on the AMT12 Base ...

Page 20: ...ttings and information The keypad functions can vary between different console models however the basic functions that all consoles have are Quickstart Incline up or down and Resistance up or down The display features can vary between different console models however the information conveyed by those displays are very similar Service software routines are handled exactly the same for all console m...

Page 21: ...take place via the keypad user input the console processor communicates that request to the processor in the lower electronics module via the serial data stream Once the lower processor receives the request the lower control module performs the machine tasks associated with the request The console processor goes about its business of monitoring keypad entry and providing display feedback The lower...

Page 22: ...istribution Once the generator s AC outputs are converted to DC there are a number of regulated DC supplies that power the various functions of the AMT The first regulated DC power supply in the distribution chain is an 18VDC supply but only supplies this 18VDC if the user is pedaling the AMT If the customer wishes to add the external power option to the AMT an external 18VDC supply replaces the 1...

Page 23: ...vel of resistance at the console and the console passes that request along to the lower control module via the serial communication through the data cable The processor on the lower control module then adjusts the output of the variable supply to an appropriate value to facilitate the user s requested resistance level That voltage is applied to an eddy current magnet pointed at the flywheel of the...

Page 24: ...s glued to outer circumference of the drum These fixed magnets are considered the primary magnetic field The outer drum of the assembly has a copper sleeve bonded to the inner circumference of the drum When the outer drum moves relative to the position of the inner drum the fixed magnets induce a current into the copper sleeve The current now flowing in the copper sleeve will produce a secondary f...

Page 25: ... a program the UPCA is going to want to use the actual stride count for its user display functions The stride is counted by the LPCA processor and transferred to the UPCA processor via the communication cable DC Lift System Motion Control If Equipped The motor used in the lift system of a self powered unit is a DC motor It is powered by 12VDC from the battery and utilizes a 7 amp self resetting fu...

Page 26: ... the data cable The processor on the lower control module then switches the 12VDC battery voltage to the lift motor windings as a POSITIVE 12VDC When the user presses the DOWN button on the console and the console passes that request along to the lower control module via the serial communication through the data cable The processor on the lower control module then switches the 12VDC battery voltag...

Page 27: ...iable voltage is applied to the input of an 8 bit A D converter which converts the analog voltage into an 8 bit binary numeric representation that the processor can understand As the voltage returned by the potentiometer changes between 0 and 3 3V DC the corresponding A D values change between 0 and 255 In this way the processor can keep track of where in the lift range the lift is truly positione...

Page 28: ...rol Error Codes Troubleshooting the Brake System Troubleshooting the Lift System Troubleshooting Communications Errors Odometer Tracking Flat Belt Replacement Event Codes Troubleshooting Heart Rate Issues Introduction The customer has reported a failed condition The failure that is reported may differ from your observations as a trained technician That is why it is important to validate the report...

Page 29: ...p the unit with the optional external power supply or have an assistant pedal the unit while voltage measurements are being taken Because of the danger of working on the unit while it is in motion using the optional external power supply is strongly recommended Perform the generator resistance test per Procedure XX If any of the resistance measurements are significantly high or significantly low r...

Page 30: ...the lower PCA refer to Diagram 8 1 1 below With an ohmmeter read between terminals 1 2 terminals 2 3 and terminals 1 3 on the six phase generator connector J1 Each of the readings should be between 26 and 30 If any of the readings are significantly high or significantly low remove the intermediate cable from the generator and perform the same measurements as in step 4 on the generator connector If...

Page 31: ...upply from its AC outlet and measure the voltage at the AC outlet If the AC outlet voltage is normal replace the optional external power supply If the AC outlet voltage is significantly low or 0 Vdc the AC system must be inspected by an electrician 5 Troubleshoot the generator per Procedure 9 2 6 If the generator was found to be good the problem will be in either the lower PCA upper PCA or the upp...

Page 32: ...wer PCA 10 Troubleshoot the upper to lower PCA interconnect cables per Procedure 9 1 11 If the upper to lower interconnect cables are found to be good replace the upper PCA 12 If you have performed all of the above tests and are unable to resolve the problem contact Precor customer support CAUTION Swapping a lower control module from a good unit into a bad unit could easily damage the lower contro...

Page 33: ... errors in the error log press and hold the reset key for at least 6 seconds If there are errors logged this action will take you into the error log The error log can also be accessed through the Information Display by pressing either pause or reset then the numbers 6 5 The following is a list of the error codes currently assigned to the AMT12 Error 05 Key depressed at power up Error 09 Memory err...

Page 34: ...rror codes will be listed with the most likely cause first and the least likely cause listed last It must be understood that this document can not anticipate every possible cause for a particular error code However it should list the causes encountered in the majority of cases The document will then list the suggested remedies associated with each of the possible causes The possible remedy listing...

Page 35: ...ot disregard the previous errors that were cleared but understand that the odometer reading when compared to the total unit odometer reading will determine how recent the error message occurred NOTE If no error codes are present but the system is not operating normally follow the troubleshooting steps for the most directly related troubleshooting topic For instance heart rate issues will not gener...

Page 36: ...led 3 Liquid perhaps perspiration is present on the surface of the display overlay Possible Remedies 1 Remove the keypad connector cable from the upper PCA Restart the power up sequence if the ERROR 5 Stuck Key is no longer present the keypad is the cause The keypad is typically part of the display housing Replace the display housing to correct the problem 2 Remove the keypad connector cable from ...

Page 37: ...s error code is only used on products utilizing the dual microprocessor system Possible Cause This error message almost always indicates a lower PCA problem when it is consistently displayed Failures causing this error message to be displayed are rare Possible Remedy If the error message is consistently displayed when the unit is powered up the lower control module should be replaced It is possibl...

Page 38: ...ible Remedies 1 If the error message is consistently displayed when the unit is powered up the lower control module should be replaced It is possible to see this message displayed intermittently due to external causes If the unit s AC input significantly dips during the power up test sequence the test could fail resulting in this message being displayed Treadmills operating on non dedicated AC cir...

Page 39: ...r 82 P30 Speed Up Not Working Error 83 P30 Speed Down Not Working Possible Causes 1 Machine control interconnect cable has come unplugged from the upper PCA 2 Bad machine control cable 3 Bad machine control assembly Possible Remedies 1 Open the P30 console to expose the circuit boards and verify that the machine control cable has not become unplugged from the upper PCA 2 Substitute a known good ma...

Page 40: ...tromagnet using clip leads and dress the leads out the back of the unit so as not to interfere with the motion of the crankarms 2 Pedal the unit to supply power and place the unit in the Hardware Validation service mode Reset 5 1 7 6 5 7 6 1 Run the Brake Test and press resistance UP until the unit is at resistance level 7 3 The voltmeter should read between 10 and 20 VDC depending on how fast you...

Page 41: ...nt This is strictly a battery problem and not a incline system or incline motor problem It is important when you start to troubleshoot the lift system to determine if the problem is due to an inability to move the lift or an inability to monitor the lift position This will determine whether you need to troubleshoot the DC voltages going to the motor windings or if you need to troubleshoot the DC v...

Page 42: ... and with an ohmmeter check the resistance The ohm value of the fuse should be less than 1 If the fuse is higher than 1 ohm replace it If the fuse is 1 ohm or less plug it back into its socket and re install the cover If the fuse is good and the lift still will not move continue to the next possible cause Newer LPCAs are equipped with a 7amp self resetting circuit breaker 2 The lower control modul...

Page 43: ...y and if it is 11 VDC or lower replace it If the battery needs to be replaced make sure that the 14 5 VDC battery charging supply is putting out 14 5 VDC If the 14 5 VDC charger voltage is not present on the lower control module replace the lower control module If the lift moves DOWN but will not move UP or has trouble moving up monitor the battery voltage while commanding the lift to move UP If t...

Page 44: ...be more likely that something has broken causing the A D value to be wrong 3 The lift motor potentiometer is bad Possible Remedies 1 Intermittent connections can be difficult to locate If the error 42 condition is intermittent a connection is almost certainly the problem This is especially true if the error 42 occurs while the lift is within its normal physical range Carefully inspect the lift pot...

Page 45: ...motor If you have performed all of the procedures above and have been unable to correct the problem search for solutions in the service bulletins or call Precor customer service Error 44 Un commanded Lift Motion Description The lift control system has detected that the lift is in motion without a lift command having been issued This can happen in one of two ways either the lift drive circuit has f...

Page 46: ...of the nature of the revolution sensor an error 44 is rarely associated with it 2 Operate the lift in the diagnostics while monitoring the lift position number being displayed If the reading is erratic and makes large changes in readings the lift position potentiometer is probably bad Replace the lift motor 3 If there is actual lift motion without a manual or program control lift command having be...

Page 47: ...ent has been initiated ramp movement will be stopped and the message ERROR 46 will be displayed Stride Height motion will not be enabled until such time as the battery voltage exceeds the above limits The battery voltage must be raised to correct this condition either by battery charging or battery replacement This is strictly a battery problem and not an incline system or incline motor problem Po...

Page 48: ...30 31 32 and 33 Communications Error Description Errors 30 through 33 all indicate the loss of communications or erratic communications between the microprocessors in the upper PCA and the lower PCA The trouble shooting procedures for all of the communication errors are essentially the same Error 30 is defined as upper PCA not receiving data from lower PCA Error 31 is defined as faulty data receiv...

Page 49: ...Disconnect the interconnect cable from the upper PCA and the lower PCA 4 External of the upper column connect a replacement interconnect cable to the lower PCA and the upper PCA 5 Check operation as described in the Operation verification section If the unit works properly replace the interconnect cable 6 If you have performed all of the procedures above and have been unable to correct the problem...

Page 50: ...ards you must remember to unplug the data cable from one board within that 20 second window before the workout summary or the odometer will be overwritten This could potentially cause all the units at the club to have incorrect odometer information and all accurate belt replacement tracking would be lost Event 78 This event is used to report that the odometer has reached 90 million strides since t...

Page 51: ...he upper PCA GEN 06 treadmill only 7 If the above procedures do not correct the problem replace the heart rate board 8 Verify that the unit does not display a heart rate with only one hand on a grip This would indicate static damage and require replacement of the heart rate board Wireless Heart Rate Does Not Work 1 Verify wireless heart rate with a known good chest strap transmitter or test transm...

Page 52: ...f interference signals are listed below 4 Using an ohmmeter verify that upper and lower PCAs have a good electrical path to chassis ground 5 If the above procedures do not correct the problem replace the heart rate board Possible sources of interference signals include BUT NOT LIMITED TO Wi Fi Network Routers Cordless Telephones Cell Phones Electronic Dog Fences Garage Door Remotes Noisy AC feeds ...

Page 53: ...13 Replacing a Front Arm Assembly Without Flat Belts and Non Press Fit Cams Prior to 4 3 2013 Replacing the Lower Board Replacing the Lower PCA and Battery Bracket Replacing the Battery Replacing th Generator Belt Replacing the Generator Replacing the Drive Input Pulley Belt Replacing the Step Up Pulley Replacing the Crank Arm Replacing the Drive Input Pulley Replacing the Lift Arm Housing Replaci...

Page 54: ...moval 1 Standing at the front of the AMT push in and then downward on the cover gasket with your thumbs until the gasket locking tabs are free of the top cover grasp the gasket and remove The gasket is split at the back to facilitate removal FIGURE 3 COVER GASKET 2 Grasp the top cover at the gasket opening and pull upward to apply pressure to the locking tabs While pressure is applied to the top c...

Page 55: ...ose end of the top cover up to apply slight pressure on the locking tabs With the heel of your hand gently tap the back cover just below the top cover see figure below The top cover should release from the back cover remove the top cover and set aside FIGURE 5 TOP COVER Front Cover Removal 1 Remove the two 10 x inch screws located at the bottom corners of front cover ...

Page 56: ...sed into the left and right side covers the markers indicate locking joints Place the heels of your hands just above the left and right side triangle markers Gently tap the triangle markers with the palm of your hand the locking tabs will release and the front can be removed FIGURE 7 SIDE COVER MARKERS AND FRONT COVER Center Beam Cover Removal 1 Remove the platform ...

Page 57: ...the cover is free from the frame Note Do not lift the cover up right after the front cover tab releases lifting up the cover too quickly may not allow the middle center beam tabs to clear the frame slots damaging the tabs FIGURE 8 CENTER BEAM COVER REMOVAL Back Cover Removal 1 Grasp the top of the rear cover and pull back the back cover will release from the locking tab and then the cover can be l...

Page 58: ...ease from the locking tabs 2 Rotate the bottom of the side cover towards the back of the AMT to remove 3 Repeat steps 1 and 2 to remove the right side cover FIGURE 10 SIDE COVER REMOVAL Left and Right Side Bottom Cover Removal 1 Remove the eight 10 x inch screws that fasten the bottom covers to the frame FIGURE 11 LEFT AND RIGHT SIDE COVER SCREW LOCATIONS 2 The left and right side bottom covers ca...

Page 59: ...over points toward the front of the AMT and the round notch in the cover points up 2 Thread the top of the side cover under the upper arm weldment and toward the front of the AMT 3 Rotate the top of the side cover up until the round notch of the side cover meets the upper arm 4 Push the bottom of the side cover in until the tabs of the side cover rest in the notches on the bottom cover 5 Repeat th...

Page 60: ... tabs of the back cover rest in the notches of the bottom covers FIGURE 14 BACK AND BOTTOM COVER ASSEMBLY 3 Rotate the back cover forward until the locking tab of the back cover is aligned with cover mounting slot of the frame push against the top of the back cover until the locking tab and slot are engaged FIGURE 15 BACK COVER LOCKING TAB ...

Page 61: ...wn on the back of the center beam cover until the locking tab of the cover has engaged with mounting slot of the frame beam 4 Replace the platform Front Cover Assembly 1 Guide the arm openings in the front cover around the arms of the AMT taking care that the tabs at the bottom corners of both openings are inside the two side covers Then guide the front cover into place until the latches on the si...

Page 62: ...rm covers to the upper arm 2 Remove the screws that fasten the outside upper arm covers to the upper arm 3 Remove the inside and outside covers from the upper arm 4 Secure the replacement cover to the arm using the five screws removed in step 1 Finger Tighten screws in all locations before fully tightening screws FIGURE 17 UPPER ARM COVER SCREW LOCATIONS ...

Page 63: ...otate the inside terminal cover down until it is below the stairarm pedal pull to remove 3 Align the top of the replacement inside cover so that it is pointing toward the floor Place the bottom of the cover in between the flat belt terminal and the stairarm pedal Rotate the top of the cover up and in to place 4 Fasten the outside and inside terminal cover to the flat belt terminal using the two 10...

Page 64: ...Remove the two screws that secure the upper arm cam covers to the upper arm remove the covers 3 Secure the replacement upper arm cam covers to the upper arm using the two screws removed in step 2 FIGURE 19 UPPER ARM CAM COVERS Top Cover Assembly Important In the following steps do not apply excessive force to seat the cover 1 Position the rear edge of the top cover so that the clips on the top and...

Page 65: ...e sure that the surfaces and edges of the gasket are flush with those on the top cover Replacing a Belt Guard Finger Guard Replacement Procedure Upper Arm Cover Removal FIGURE 20 UPPER ARM COVERS 1 Remove the four screws that fasten the inside upper arm covers to the upper arm 2 Remove the screw that fasten the outside upper arm covers to the upper arm 3 Remove the inside and outside covers from t...

Page 66: ...ion Prohibited by Law Page 66 Belt Guard Removal 5 Grasp the belt guard mounting rings located on each side of the upper arm Gently pull out and away from the grip connection ring s just enough to extend past the mounting bolt FIGURE 22 BELT GUARD AND UPPER ARM ...

Page 67: ...elease locking tabs and rotate two halves down c Taking care to not lose the rollers inside the belt guard pull the two belt guard halves away from each other to separate FIGURE 23 BELT GUARD REMOVAL 7 Place the two sections of the replacement belt guard so they are positioned around the flat belt just below the upper arm The front belt guard should be positioned so that the interlocking tabs are ...

Page 68: ... rotate the halves together around the flat belt until the locking tabs are locked FIGURE 24 BELT GUARD INTERLOCKING TABS AND SLOTS 8 Grasp each belt guard mounting ring lift the belt guard into position over the upper arm mounting bolts and then secure each mounting ring to the connection ring FIGURE 25 BELT GUARD MOUNTING 9 Replace the upper arm covers as per procedure Upper Arm Cover Replacemen...

Page 69: ...r Arm Cover Removal FIGURE 26 UPPER ARM COVERS 1 Remove the four screws that fasten the inside upper arm covers to the upper arm 2 Remove the screw that fasten the outside upper arm covers to the upper arm 3 Remove the inside and outside covers from the upper arm 4 Repeat the process for the remaining upper arm covers FIGURE 27 UPPER ARM COVER SCREW LOCATIONS ...

Page 70: ...ion Prohibited by Law Page 70 Belt Guard Removal 5 Grasp the belt guard mounting rings located on each side of the upper arm Gently pull out and away from the grip connection ring s just enough to extend past the mounting bolt FIGURE 28 BELT GUARD AND UPPER ARM ...

Page 71: ... can be removed from flat belt a Lower the belt guard down just below the upper arm b Squeeze the belt guard near the base to release locking tabs and rotate the two halves down c Taking care to not lose the rollers inside the belt guard pull the two belt guard halves away from each other to separate 7 Repeat the process for the remaining belt guard FIGURE 29 BELT GUARD REMOVAL ...

Page 72: ...moval 8 Remove the two 10 24X 75 screws that secure the grip to the upper arm there is one screw on each side of the upper arm FIGURE 30 UPPER ARM GRIP SCREW LOCATIONS 9 Grasp the grip connecting ring located on each side of the upper arm pull up and over the flat belt pulley mounting bolt to remove the grip ...

Page 73: ...crews Repeat the process for the remaining upper arm grip Belt Guard Installation 12 Place the two halves of the belt guard so they are positioned around the flat belt just below the upper arm The smaller half should be positioned so that the interlocking tabs are pointing toward the front of the machine and the guard toward the back The larger half should be positioned with the guard toward the f...

Page 74: ...r arm covers as per procedure Upper Arm Cover Replacement on page 61 Replacing a Flat Belt Terminal Flat Belt Terminal Replacement Procedure Rear Flat Belt Terminal Cover Removal 1 Remove the two 10 24 X 1 25 screws that secure the flat belt terminal covers to the flat belt terminal remove the outside terminal cover 2 Rotate the top of the inside terminal cover down until it is below the stairarm ...

Page 75: ...rom the inner flat belt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down 5 Remove the flat belt terminal stop bolt and washer 6 Remove the flat belt terminal adjustment bolt and washer FIGURE 34 FLAT BELT CLAMP AND FLAT BELT TERMINAL ...

Page 76: ... GPOR1 synthetic polymeric grease to the flat belt terminal shaft 9 Carefully slide on the anti rotation disc and flat belt terminal Do not use excessive force Fasten the anti rotation disc and replacement flat belt terminal onto the stairarm using the washer and mounting bolt removed in step 5 torque to 300 inch pounds or 25 foot pounds 10 Fasten the stop bolt and washer to the flat belt clamp bu...

Page 77: ... stairarm adjustment stop bolt 14 Push one of the stairarm pedal s down to its lowest level Measure the distance from the bottom of the stairarm tube to the top of the center beam frame the distance between the stairarm tube and the center beam frame should be 3 7 8 inches FIGURE 36 STAIRARM HEIGHT MEASUREMENT 15 If the measurement is too low or too high tighten or loosen the adjustment bolt until...

Page 78: ...rque to 300 inch pounds or 25 foot pounds Rear Flat Belt Terminal Cover Installation 1 Align the top of the replacement inside cover so that it is pointing toward the floor Place the bottom of the cover in between the flat belt terminal and the stairarm pedal Rotate the top of the cover up and in to place 2 Fasten the outside and inside terminal cover to the flat belt terminal using the two 10 24 ...

Page 79: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 79 FIGURE 38 FLAT BELT TERMINAL COVERS ...

Page 80: ...lt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down Upper Arm Cover Removal FIGURE 39 UPPER ARM COVERS 3 Remove the four screws that fasten the inside upper arm covers to the upper arm 4 Remove the screw that fasten the outside upper arm covers to the upper arm 5 Remove the inside and outside covers from the upper arm...

Page 81: ...ion Prohibited by Law Page 81 Belt Guard Removal 7 Grasp the belt guard mounting rings located on each side of the upper arm Gently pull out and away from the grip connection ring s just enough to extend past the mounting bolt FIGURE 41 BELT GUARD AND UPPER ARM ...

Page 82: ... can be removed from flat belt a Lower the belt guard down just below the upper arm b Squeeze the belt guard near the base to release locking tabs and rotate the two halves down c Taking care to not lose the rollers inside the belt guard pull the two belt guard halves away from each other to separate 9 Repeat the process for the remaining belt guard FIGURE 42 BELT GUARD REMOVAL ...

Page 83: ...s and the pulley shaft from the upper arm FIGURE 44 UPPER ARM FLAT BELT PULLEY REMOVED 12 Slide the pulley shaft into the flat belt pulley place one spacer on each side of the flat belt pulley Ensure the belt goes over the top of the pulley Insert the assembly into the upper arm 13 Secure the flat pulley assembly to the upper arm using the mounting bolt washers and lock nut Thread the mounting bol...

Page 84: ...d the flat belt just below the upper arm The smaller half should be positioned so that the interlocking tabs are pointing toward the front of the machine and the guard toward the back The larger half should be positioned with the guard toward the front Align the interlocking tabs of the smaller half with the slots of the larger half rotate the halves together around the flat belt until the locking...

Page 85: ...ution Prohibited by Law Page 85 FIGURE 46 UPPER ARM COVER SCREW LOCATIONS 19 Lift the stairarms and then thread the flat belts over the flat belt pulleys 20 Replace the main body covers asp per procedure Cover Replacement on page 53 Replacing a Stairarm Pedal ...

Page 86: ...nt holds the stairarm up 2 Remove the four screws washers and washer plate that secure the stairarm pedal to the stairarm remove the stairarm pedal 3 Fasten the replacement stairarm pedal to the stairarm using the four screws washers and washer plate removed in step 2 4 Torque the screws to 15 inch pounds starting from the single screw at the end of the stairarm than screw mounted in the middle fi...

Page 87: ...ent Procedure Rear Flat Belt Terminal Cover Removal 1 Remove the two 10 24 X 1 25 screws that secure the flat belt terminal covers to the flat belt terminal remove the outside terminal cover 2 Rotate the top of the inside terminal cover down until it is below the stairarm pedal pull to remove 3 Repeat the process for the remaining rear flat belt terminal cover ...

Page 88: ...rohibited by Law Page 88 FIGURE 50 FLAT BELT TERMINAL COVERS Flat Belt Terminal Removal 4 Remove the mounting bolt and washer that secure the flat belt terminal to the stairarm remove the flat belt terminal and anti rotation disc FIGURE 51 FLAT BELT TERMINAL REMOVAL ...

Page 89: ... it You may have to rotate the bearing one full turn to align the bearing lock hole with drain hole 6 Once the screwdriver has locked the bearing preventing further rotation fully remove the inside and outside mounting bolts Remove the stairarm FIGURE 52 STAIRARM AND FRONT ARM SCREW LOCATIONS Stairarm Pedal Removal 7 Pivot the stairarm up into a vertical position Note The following procedure will ...

Page 90: ...ed by Law Page 90 FIGURE 53 STAIRARM AND STAIRARM PEDAL SCREW LOCATIONS Stairarm Knuckle Cover Removal 9 Remove the two 10 24 X 75 screws that secure the stairarm knuckle cover to the stairarm and set aside the knuckle cover FIGURE 54 STAIRARM KNUCKLE COVER SCREW LOCATIONS ...

Page 91: ...irarm using the two 10 24 X 75 Stairarm Pedal Installation 11 Fasten the replacement stairarm pedal to the stairarm using the four screws and washers removed in step 2 12 Torque the screws to 25 inch pounds starting from the single screw at the end of the stairarm then the two camp screws finally the two rear pedal screws FIGURE 55 STAIRARM AND STAIRARM PEDAL SCREW LOCATIONS ...

Page 92: ... to rotate the bearing one full turn to align the bearing lock hole with drain hole 15 Once the screwdriver has locked the bearing preventing further rotation fully tighten the inside and outside mounting bolts torque to 83 foot pounds or 1000 inch pounds 16 Remove the screwdriver from the drain hole Rear Flat Belt Terminal Installation 17 Carefully slide on the anti rotation disc and flat belt te...

Page 93: ...ting toward the floor Place the bottom of the cover in between the flat belt terminal and the stairarm pedal Rotate the top of the cover up and in to place 19 Fasten the outside and inside terminal cover to the flat belt terminal using the two 10 24 X 1 25 screws FIGURE 57 FLAT BELT TERMINAL COVERS Lift the stairarms and then thread the flat belts over the flat belt pulleys Replacing the Flat Belt...

Page 94: ...t reset has not been issued through software diagnostics the AMT will lock out the display with an out of service replace flat belts message The stride count odometer is now stored on both the upper PCA and Lower PCA The dual memory locations allow the stride count to be transferred in the event that an upper PCA or lower PCA is replaced If the upper PCA is replaced the stride count stored on the ...

Page 95: ...complete make sure that each PCA board is replaced in the original unit from which it was removed The only exception to this would be if you find a bad board that needs to be replaced All of these functions will place a code 70 79 in the error log and they should be cleared before returning the unit to use The following table shows the possible belt and PCA board swapping event codes Belt Replacem...

Page 96: ...f the UPCA and the UPCA is less than 30 000 strides The LPCA stride count record is written to the UPCA 75 LPCA stride count is less than 30 000 strides and is lower than that of the UPCA The UPCA stride count record is written to the LPCA 76 LPCA stride count is greater than that of the UPCA and UPCA stride count is greater than 30 000 The UPCA stride count record is written to the LPCA 77 UPCA s...

Page 97: ...off the flat belt pulleys and then gently setting the stairarm down Flat Belt Removal Front Clamp 4 Remove the two mounting bolts and washers that secure the front flat belt clamp to the platform FIGURE 59 FRONT BELT CLAMPS Note Any time the flat belt terminal screws are removed from the flat belt clamp or cams the screws must be discarded and replaced with new screws 5 Temporarily reinstall the t...

Page 98: ...pin from the flat belt loop and clamp and then slide the flat belt out of the clamp Upper Arm Cam Cover Removal 8 Remove the two 10 24X1 25 screws that secure the upper arm cam covers to the upper arm then remove the covers It may be necessary to adjust the position of the vertical handlebar to gain access to the upper arm cam cover screws FIGURE 61 UPPER ARM CAM COVERS ...

Page 99: ...ams the screws must be discarded and replaced with new screws 9 Remove and discard the two 1 4 20X1 flat belt cam clamp screws and shims that secure the flat belt to the clamp FIGURE 62 UPPER INSIDE CAM SCREW REMOVAL 10 Using a screw driver tip push out the pin from the flat belt loop and cam clamp and then slide the flat belt out of the cam clamp Remove the flat belt FIGURE 63 UPPER INSIDE CAM PI...

Page 100: ...nt marker draw a line across the flat belt at 10 inches Repeat this process for the other end of the flat belt FIGURE 64 FLAT BELT END MEASUREMENT 12 Place the inside flat belt on the cam so the length of the flat belt is draped towards the back of the AMT Make sure the smooth side of the flat belt contacts the cam and the segmented side is facing up 13 Install a replacement 1 4 20X1 screw and shi...

Page 101: ...into the cam clamp A 1 2 inch deep set socket can be used to assist in pushing the belt into place When the flat belt loop is about half way into the cam clamp push the pin into the flat belt loop 15 Continue to work the flat belt loop and pin into the cam clamp until the side of the flat belt is resting next to the clamp screw Ensure the pin is centered within the cam clamp FIGURE 66 UPPER INSIDE...

Page 102: ...nside Flat Belt Routing 17 Route the flat belt over the top of the cam towards the back of the AMT and down over the first flat belt pulley then under the second flat belt pulley to the front belt clamp If the flat belts are not long enough to route through the pulley s skip the belt routing until the belt flat belt installation is completed FIGURE 67 INSIDE FLAT BELT ROUTING ...

Page 103: ...belt loop is about half way into the terminal clamp push the pin into the flat belt loop 20 Continue to work the flat belt loop and pin into the terminal clamp until the side of the flat belt is resting next to the clamp screw Ensure the pin is centered within the terminal clamp FIGURE 68 FRONT FLAT BELT CLAMP PIN MOUNTING 21 Install the second1 4 20X1 screw and shim that secure the flat belt to t...

Page 104: ...sing downward pressure on the stairarm pedal while closely monitoring the flat belt ends for movement through the belt clamps 24 Monitor the movement of the belt through the clamps until one or both ends of the flat belt has one belt segment extending beyond the flat belt clamp FIGURE 69 FLAT BELT END ALIGNMENT ...

Page 105: ...que to 120 inch pounds 26 Resume applying downward pressure to the stairarm pedal until the remaining flat belt end reaches the one segment measurement Tighten the two flat belt screws and torque to 120 inch pounds 27 Remove the mounting bolts that secure the inside flat belt clamp to the frame replace the washers and reinstall the mounting bolts Torque to 300 inch pounds 28 If the flat belt was n...

Page 106: ...Upper Arm Cover Removal FIGURE 70 UPPER ARM COVERS 1 Remove the four screws that fasten the inside upper arm covers to the upper arm 2 Remove the screw that fasten the outside upper arm covers to the upper arm 3 Remove the inside and outside covers from the upper arm 4 Repeat the process for the remaining upper arm covers ...

Page 107: ... Page 107 FIGURE 71 UPPER ARM COVER SCREW LOCATIONS Belt Guard Removal 1 Grasp the belt guard mounting rings located on each side of the upper arm Gently pull out and away from the grip connection rings just enough to extend past the mounting bolt FIGURE 72 BELT GUARD AND UPPER ARM ...

Page 108: ...oved from flat belt a Lower the belt guard down just below the upper arm b Squeeze the belt guard near the base to release locking tabs and rotate the two halves down c Taking care to not lose the rollers inside the belt guard pull the two belt guard halves away from each other to separate 3 Repeat the process for the remaining belt guard FIGURE 73 BELT GUARD REMOVAL Upper Arm Grip Removal ...

Page 109: ...screws that secure the grip to the upper arm there is one screw on each side of the upper arm FIGURE 74 UPPER ARM GRIP SCREW LOCATIONS 5 Grasp the grip connecting ring located on each side of the upper arm pull up and over the flat belt pulley mounting bolt to remove the grip FIGURE 75 UPPER ARM GRIP REMOVAL ...

Page 110: ...inal Cover Removal 7 Remove the two 10 24 X 1 25 screws that secure the flat belt terminal covers to the flat belt terminal remove the outside terminal cover 8 Rotate the top of the inside terminal cover down until it is below the stairarm pedal pull to remove 9 Repeat the process for the remaining rear flat belt terminal cover FIGURE 76 FLAT BELT TERMINAL COVERS ...

Page 111: ... be discarded and replaced with new screws 10 Remove and discard the two 1 4 20X1 screws and shims that secure the flat belt to the clamp FIGURE 77 FLAT BELT REMOVAL TERMINAL 11 Using a screwdriver push out the pin from the flat belt loop and clamp and then slide the flat belt out of the clamp A 1 2 inch socket will fit the inside diameter of the flat belt clamp and can be used to push the flat be...

Page 112: ...lt has already been removed you can use a fish tape or coat hanger to pull the belt through the upper arm Ensure the flat belt is routed over the top of any hardware that may be crossing the inside of the upper arm 12 If the flat belt cannot be pulled through the upper arm by taping a new belt to the old belt or with a fish tape continue with the next steps otherwise skip to the Flat Belt Removal ...

Page 113: ...m 15 Repeat the process for the remaining flat belt pulley FIGURE 80 UPPER ARM FLAT BELT PULLEY REMOVED Flat Belt Removal Upper Arm Cam Note Any time the flat belt terminal screws are removed from the flat belt clamp or cams the screws must be discarded and replaced with new screws 16 Remove and discard the two 1 4 20X1 screws and shims that secure the flat belt to the cam clamp ...

Page 114: ...d Distribution Prohibited by Law Page 114 FIGURE 81 UPPER OUTSIDE CAM SCREW REMOVAL 17 Using a screwdriver push out the pin from the flat belt loop and cam clamp and then slide the flat belt out of the cam clamp FIGURE 82 UPPER OUTSIDE CAM PIN REMOVAL ...

Page 115: ...or coat hanger to pull the belt through the upper arm Ensure the flat belt is routed over the top of any hardware that may be crossing the inside of the upper arm 18 Grasp the loose end of the flat belt from the back end of the upper arm and then pull the belt through the arm to remove Note the flat belt must be routed over the strut in the front arm assembly Failure to route the flat belt over th...

Page 116: ...ght edge and permanent marker draw a line across the flat belt at 10 inches Repeat this process for the other end of the flat belt 20 Place the inside flat belt on the cam so the length of the flat belt is draped towards the back of the AMT Make sure the smooth side of the flat belt contacts the cam and the segmented side is facing up FIGURE 84 OUTSIDE FLAT BELT ROUTING CAM 21 Install a replacemen...

Page 117: ...is time Flat Belt Pulley Installation 25 Slide the pulley shaft into the flat belt pulley and place one spacer on each side of the flat belt pulley Ensure the belt goes over the top of the pulley Insert the assembly into the upper arm 26 Secure the flat belt pulley assembly to the upper arm using the mounting bolt washers and lock nut Thread the mounting bolt from the inside of the upper arm towar...

Page 118: ... the pin is centered within the terminal clamp FIGURE 86 FLAT BELT TERMINAL PIN 31 Install the second 1 4 20X1 replacement screw and shim that secure the flat belt to the terminal clamp Do not fully tighten at this time Outside Flat Belt Alignment 32 The flat belts ends will now need to be adjusted to their final position before the flat belt clamp screws can be fully tightened Gently press down o...

Page 119: ...ume applying downward pressure to the stairarm pedal until the remaining flat belt end reaches the one segment measurement Tighten the two flat belt screws and torque to 120 inch pounds 36 Repeat the procedure for the remaining outside flat belt replacement Adjusting the Stairarm Pedal Height 37 Loosen but do not remove the stairarm adjustment stop bolt 38 Push one of the stairarm pedal s down to ...

Page 120: ... HEIGHT MEASUREMENT 39 If the measurement is too low or too high tighten or loosen the adjustment bolt until the 3 7 8 inch measurement is achieved FIGURE 89 FLAT BELT TERMINAL ADJUSTMENT 40 Repeat the process for the remaining stairarm 41 Fully tighten the stop bolt torque to 300 inch pounds or 25 foot pounds ...

Page 121: ...the upper arm The smaller half should be positioned so that the interlocking tabs are pointing toward the front of the machine and the guard toward the back The larger half should be positioned with the guard toward the front Align the interlocking tabs of the smaller half with the slots of the larger half rotate the halves together around the flat belt until the locking tabs are locked FIGURE 90 ...

Page 122: ...ge 64 48 Secure the belt keeper to the frame 49 At the console enter the access code PAUSE 5 1 7 6 5 7 6 1 to enter into the diagnostics software Navigate to the STRIDE COUNT RESET section and reset the flat belt stride count 50 Replace the main body covers as per procedure Cover Replacement on page 53 51 Check the operation of the AMT12 Replacing the Front Arm Assemblies With Flat Belts and Press...

Page 123: ...ver at the gasket opening and pull upward to apply pressure to the locking tabs While pressure is applied to the top cover gently tap the front cover just below the top cover with the heel of your hand See figure below FIGURE 93 FRONT TOP COVER RELEASE 3 Standing at the side of the AMT pull the loose end of the top cover up to apply slight pressure on the locking tabs With the heel of your hand ge...

Page 124: ...ont cover FIGURE 95 FRONT COVER SCREW LOCATIONS 2 There are two triangle markers embossed into the left and right side covers the markers indicate locking joints Place the heels of your hands just above the left and right side triangle markers Gently tap the triangle markers with the palm of your hand the locking tabs will release and the front can be removed ...

Page 125: ...ter beam cover lift the cover up slightly until the locking tab is clear of the frame 5 Pull the center beam cover back toward you until the cover is free from the frame Note Do not lift the cover up right after the front cover tab releases lifting up the cover too quickly may not allow the middle center beam tabs to clear the frame slots damaging the tabs ...

Page 126: ...out of the slots in the bottom covers 7 Grasp each side of the left side cover near the bottom lift up and then pull the bottom of the cover out and away from the frame The cover will release from the locking tabs 8 Rotate the bottom of the side cover towards the back of the AMT to remove 9 Repeat steps 1 and 2 to remove the right side cover 10 Remove the eight 10 x inch screws that fasten the bot...

Page 127: ...me and remove the belt keeper 13 Remove the tension from the inner flat belt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down Upper Arm Cam Cover Removal 14 Remove the two 10 24X1 25 screws that secure the upper arm cam covers to the upper arm then remove the covers It may be necessary to adjust the position of the ve...

Page 128: ...emoval 16 Remove the two 10 24 X 1 25 screws that secure the flat belt terminal covers to the flat belt terminal remove the outside terminal cover 17 Rotate the top of the inside terminal cover down until it is below the stairarm pedal pull to remove 18 Repeat the steps for the remaining rear flat belt terminal covers FIGURE 99 FLAT BELT TERMINAL COVERS ...

Page 129: ...bolts that adjust and secure the flat belt clamps to the flat belt terminals FIGURE 100 FLAT BELT CLAMP AND FLAT BELT TERMINAL Upper Arm Cover Removal 2 Remove the four screws that fasten the inside upper arm covers to the upper arm 3 Remove the screw that fasten the outside upper arm covers to the upper arm ...

Page 130: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 130 4 Remove the inside and outside covers from the upper arm FIGURE 101 UPPER ARM COVER SCREW LOCATIONS ...

Page 131: ...tion Prohibited by Law Page 131 1 Repeat the steps for the remaining front arm covers Upper Arm Grip Removal 2 Remove the two screws that secure the grip to the upper arm there is one screw on each side of the upper arm FIGURE 102 UPPER ARM GRIP SCREW LOCATIONS ...

Page 132: ...d Reproduction and Distribution Prohibited by Law Page 132 3 Grasp the grip connecting ring located on each side of the upper arm pull up and over the flat belt pulley mounting bolt to remove the grip FIGURE 103 UPPER ARM GRIP REMOVAL ...

Page 133: ...133 4 Repeat the steps for the remaining front arm grip Belt Guard Removal 5 Grasp the belt guard mounting rings located on each side of the upper arm Gently pull out and away from the grip connection ring s just enough to extend past the mounting bolt FIGURE 104 BELT GUARD AND UPPER ARM ...

Page 134: ...the upper arm b Squeeze the belt guard near the base to release locking tabs and rotate the two halves down c Taking care to not lose the rollers inside the belt guard pull the two belt guard halves away from each other to separate FIGURE 105 BELT GUARD REMOVAL Upper Arm Flat Belt Pulley Removal 7 Remove the mounting bolts the two washers and the nut that secure the upper arm pulleys to the upper ...

Page 135: ... 8 Slide out the upper arm pulleys the two spacers and the pulley shaft from the upper arms FIGURE 107 UPPER ARM FLAT BELT PULLEY REMOVED Front Flat Belt Terminal Removal 9 Remove the bolts and washers that secures the front flat belt clamps to the lift platform FIGURE 108 FRONT BELT CLAMPS ...

Page 136: ...ngages into the bearing and locks it You may have to rotate the bearing one full turn to align the bearing lock hole with drain hole 11 Once the screwdriver has locked the bearing preventing further rotation fully remove the inside and outside mounting bolts Remove the stairarm 12 Repeat the steps for the remaining stairarm FIGURE 109 STAIRARM AND FRONT ARM SCREW LOCATIONS 13 Remove the vertical h...

Page 137: ...he outside cam tubes to the upper arms Note This step must be performed before the main shaft clamp is removed otherwise the shaft will rotate when the bolt is turned and you will not be able to be remove the bolt FIGURE 111 FRONT ARM MOUNTING BOLT 16 Remove the six bolts that secure the upper main shaft clamp to the lower main shaft clamp Remove the top main shaft clamp ...

Page 138: ...ent belt to the old flat belt at the cam side and then pull the new belt through the upper arm as the old belt is removed If the belt has already been removed you can use a fish tape or coat hanger to pull the belt through the upper arm Ensure the flat belt is routed over the top of any hardware that may be crossing the inside of the upper arm 17 With assistance lift the front arm and flat belts o...

Page 139: ...t the right front arm assembly next to one of the front arms while feeding the outside flat belt through the upper arm Note the flat belt must be routed over the strut in the front arm assembly Failure to route the flat belt over the strut will cause severe damage to the flat belt The Figure below illustrates the correct flat belt routing ...

Page 140: ...TING TRANSPARENT VIEW OF ARM 20 With assistance lift the front arm and place it into the main shaft clamp and upper arm Repeat the process for the remaining front arm assembly FIGURE 115 FRONT ARM SHAFT AND MAIN CLAMP 21 Insert and finger tighten the shoulder bolts that secure the outside cam tubes to the upper arms ...

Page 141: ...G BOLT 22 Insert and finger tighten the six main arm shaft bolts that secure the main shaft clamp to the lower main shaft clamp 23 Use the following sequence to ensure the upper arm main shaft is properly secured to the front arm shaft torque the bolts to 160 inch pounds FIGURE 117 MAIN SHAFT CLAMP BOLTS TORQUE SEQUENCE ...

Page 142: ...at belt pulley Note The lock nut should be on the outside of the upper arm Upper Arm Grip Installation 28 Grasp the grip connecting ring located on each side of the upper arm grip pull out and place the grip over the flat belt pulley mounting bolt 29 Secure the upper arm grip to the upper arm using the two 10 24X 75 screws 30 Repeat the steps for the remaining arm grip Belt Guard Installation 31 P...

Page 143: ...the drain hole on the bottom of the front arm and thread one of the two 1 2 13X1 screws into stairarm Using the installed screw rotate the front arm bearing until the screw driver engages into the bearing locking the bearing You may have to rotate the bearing one full turn to align the bearing lock hole with drain hole 37 Once the screwdriver has locked the bearing preventing further rotation full...

Page 144: ...ed correctly through the pulleys See illustration below for proper flat belt routing FIGURE 120 FLAT BELTS 41 Secure the front flat belts terminals to platform FIGURE 121 FRONT BELT CLAMPS Tie Rod Installation 42 Fasten each upper tie rod end to the cam assembly using the bolts and washers torque the bolt to 300 inch pounds ...

Page 145: ...o bolts and washers that adjust and secure the flat belt clamp to the flat belt terminal 44 Push one of the stairarm pedal s down to its lowest level Measure the distance from the bottom of the stairarm tube to the top of the center beam frame the distance between the stairarm tube and the center beam frame should be 3 7 8 inches FIGURE 123 STAIRARM HEIGHT MEASUREMENT ...

Page 146: ...overs 49 Replace the body covers 50 Replace the vertical handle bars 51 At the console enter the access code PAUSE 5 1 7 6 5 7 6 1 to enter into the diagnostics software Navigate to the STRIDE COUNT RESET section and reset the flat belt stride count 52 Fully check the operation of the AMT Replacing a Front Arm Assembly Without Flat Belts and Non Press Fit Cams Prior to 4 3 2013 Caution Replace onl...

Page 147: ...emove the tension from the inner flat belt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down Upper Arm Cam Cover Removal 3 Remove the two 10 24X1 25 screws that secure the upper arm cam covers to the upper arm then remove the covers It may be necessary to adjust the position of the vertical handlebar to gain access to ...

Page 148: ...outside mounting bolt that secures the front arm to the stairarm until the screw driver engages into the bearing and locks it You may have to rotate the bearing one full turn to align the bearing lock hole with drain hole 5 Once the screwdriver has locked the bearing preventing further rotation fully remove the inside and outside mounting bolts Remove the stairarm FIGURE 125 STAIRARM AND FRONT ARM...

Page 149: ...eplaced with new screws 7 Remove and discard the two 1 4 20X1 flat belt cam clamp screws and shims that secure the flat belt to the clamp FIGURE 126 UPPER INSIDE CAM SCREW REMOVAL 8 Using a screw driver tip push out the pin from the flat belt loop and cam clamp and then slide the flat belt out of the cam clamp Remove the flat belt FIGURE 127 UPPER INSIDE CAM PIN REMOVAL 9 Repeat the process to rem...

Page 150: ...w Page 150 Tie Rod Removal 10 Remove the tie rod mounting bolt and washer that secures the upper tie rod end to the upper arm axle FIGURE 128 TIE RODS Front Arm Removal 11 Remove the shoulder bolt that secures the outside cam tube to the upper arm FIGURE 129 FRONT ARM MOUNTING BOLT ...

Page 151: ...Prohibited by Law Page 151 12 Remove the six bolts that secure the upper main shaft clamp to the lower main shaft clamp Remove the top main shaft clamp FIGURE 130 MAIN SHAFT CLAMP BOLTS Caution It is recommended to have assistance available for the following step s ...

Page 152: ...removal steps 1 Diagnostics Mark the sides of the inside and outside cams with a notation to indicate the sides facing away from the front arm tube For example mark the outside cam with an O and the inside with an I FIGURE 131 FRONT ARM CAM ORIENTATION Note Any time the flat belt terminal screws are removed from the flat belt clamp or cams the screws must be discarded and replaced with new screws ...

Page 153: ...ront arm tube Align the flat belt cam alignment slot with the square key mounted in the front arm tube slide the flat belt cam onto the front arm tube Do not use excessive force to install the cams Note Ensure that the cam is fully seated so that the side of the cam is flush with the side of the front arm tube 2 Fasten the flat belt cam to the front arm tube using the two replacement screws and sh...

Page 154: ...re the flat belts are positioned correctly before installing the front arm With assistance lift the front arm and then set the front arm into the lower main shaft clamp and upper arm FIGURE 134 FRONT ARM SHAFT AND MAIN CLAMP 5 Insert and finger tighten the bolt for the outside cam tube to the upper arm ...

Page 155: ...ence to ensure the upper arm main shaft is properly secures to the front arm shaft torque the bolts to 160 inch pounds FIGURE 135 MAIN SHAFT CLAMP BOLTS TORQUE SEQUENCE 7 Secure the front arm shaft to the upper arm using the shoulder bolt torque to 300 inch pounds or 25 foot pounds FIGURE 136 FRONT ARM MOUNTING BOLT ...

Page 156: ...ed Unauthorized Reproduction and Distribution Prohibited by Law Page 156 Tie Rod Installation 8 Fasten upper tie rod end to the cam assembly with the bolt and washer torque the bolt to 300 inch pounds FIGURE 137 TIE RODS ...

Page 157: ...t marker draw a line across the flat belt at 10 inches Repeat this process for the other end of the flat belt FIGURE 138 FLAT BELT END MEASUREMENT 2 Place the inside flat belt on the cam so the length of the flat belt is draped towards the back of the AMT Make sure the smooth side of the flat belt contacts the cam and the segmented side is facing up 3 Install a replacement 1 4 20X1 screw and shim ...

Page 158: ...into the cam clamp A 1 2 inch deep set socket can be used to assist in pushing the belt into place When the flat belt loop is about half way into the cam clamp push the pin into the flat belt loop 5 Continue to work the flat belt loop and pin into the cam clamp until the side of the flat belt is resting next to the clamp screw Ensure the pin is centered within the cam clamp FIGURE 140 UPPER INSIDE...

Page 159: ...1 4 20X1 screw and shim that secures the flat belt to the cam tighten and torque both screws to 120 inch pounds 7 Thread the outside flat belt so that the belt is routed from under the cam toward the front of the AMT and then up ensure the flat belt loop end is facing up FIGURE 141 OUTSIDE FLAT BELT ROUTING CAM ...

Page 160: ...the cam clamp Flat Belt Installation Upper Arm Cam 10 Lay the replacement flat belt on a flat surface with the flat belt segments facing up Measure the distance in from the end of the flat belt 10 inches using a straight edge and permanent marker draw a line across the flat belt at 10 inches Repeat this process for the other end of the flat belt 11 Place the inside flat belt on the cam so the leng...

Page 161: ...rk work the loop into the cam clamp A 1 2 inch deep set socket can be used to assist in pushing the belt into place When the flat belt loop is about half way into the cam clamp push the pin into the flat belt loop 14 Continue to work the flat belt loop and pin into the cam clamp until the side of the flat belt is resting next to the clamp screw FIGURE 143 UPPER OUTSIDE CAM PIN 15 Install the secon...

Page 162: ...the bearing You may have to rotate the bearing one full turn to align the bearing lock hole with drain hole 18 Once the screwdriver has locked the bearing preventing further rotation fully tighten the inside and outside mounting bolts torque to 83 foot pounds or 1000 inch pounds 19 Remove the screwdriver from the drain hole FIGURE 144 STAIRARM AND FRONT ARM SCREW LOCATIONS 20 Lift the stairarm and...

Page 163: ...cking pressure tabs located on each side of the lower PCA cover push the two locking tabs outward and pull up the bottom of the lower PCA cover 3 Rotate the bottom of the lower PCA cover up until the two hooks of the cover disengage from the lower PCA bracket FIGURE 145 LOWER PCA COVER Removing the Lower PCA 1 Attach the wrist ESD strap to your arm and then connect the ground wire of the wrist str...

Page 164: ...nly generator cable load cable stride dial cable battery cables and vertical sensor cable from the lower PCA 8 Reinstall the lower PCA cover by interlocking the PCA cover hooks and the PCA bracket hangers lower the cover until the locking tabs engage FIGURE 146 LOWER PCA Replacing the Lower PCA and Battery Bracket Procedure 1 Remove the main body covers as per procedure Cover Replacement on page 5...

Page 165: ...me 6 Carefully disengage wires form the securing clips on the lower PCA battery bracket FIGURE 147 LOWER PCA AND BATTERY BRACKET 7 Lift the bracket up and off the generator bracket Battery Bracket Installation 8 Align the Lower PCA mounting tabs with the generator bracket then slide the bracket down onto the generator bracket Note Ensure that the wires are not pinched between the generator bracket...

Page 166: ...bracket 13 Replace the lower PCA cover as per procedure Lower PCA Cover see Removing the Lower PCA Cover on page 163 14 Replace the covers as per procedure Cover Replacement on page 53 Replacing the Battery Procedure 1 Remove the covers as per procedure Cover Replacement on page 53 2 Remove the lower PCA cover Lower PCA Cover see Removing the Lower PCA Cover on page 163 3 Disconnect the two batter...

Page 167: ...rms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down 3 Loosen the generator mounting bolts 4 Loosen the generator adjustment bolt until the top of the bracket slots are resting on the generator mounting bolts 5 Loosen the step up pulley mounting bolts 6 Loosen the step up pulley adjustment bolt until tension has been removed from the input pulley belt and ...

Page 168: ... the belt is seated in the grooves of both pulleys 10 Replace the input drive belt Removed in step7 over the smaller side of the step up pulley 11 Adjust the Input pulley tension Go to Inspecting and Adjusting the Input Belt Tension procedure 12 Tighten the two step up pulley mounting bolts Torque to 160 inch pounds 13 Install the generator belt over the step up pulley and generator pulley 14 Adju...

Page 169: ...nsion FIGURE 151 GENERATOR 18 The drive input belt tension should read approximately 120 10 lbs and the generator belt tension should read approximately 90 10 lbs See Drive Belt Gauge Instructions on page 265 for attaining maximum accuracy from the gauge 19 Lift the stairarms and then thread the flat belts over the flat belt pulleys 20 Replace the covers as per procedure Cover Replacement on page ...

Page 170: ...s remove the generator belt from the generator pulley 6 Remove the two generator mounting bolts and remove generator 7 Secure the replacement generator using the two generator mounting bolts removed in the previous step do not fully tighten at this time 8 Replace the tension plate in the mounting slot in the generator 9 Thread the tension bolt and washer through the frame mount bracket and generat...

Page 171: ...re 1 Remove the covers as per procedure Cover Replacement on page 53 2 Remove the tension from the inner flat belt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting down the stairarm 3 Loosen the generator mounting bolts 4 Loosen the generator adjustment bolt until the top of the bracket slots are resting on the generator mounting bolts...

Page 172: ...ad the flat belts over the flat belt pulleys 12 Select the QUICKSTART program and adjust the resistance up key until resistance level 10 is displayed Pedal the AMT for approximately one minute and then recheck the belt tension FIGURE 154 GENERATOR 13 The drive input belt tension should read approximately 120 10 lbs and the generator belt tension should read approximately 90 10 lbs See Drive Belt G...

Page 173: ...ounting bolts FIGURE 155 GENERATOR 5 Loosen the two step up pulley mounting bracket bolts 6 Loosen the step up pulley adjustment bolt until tension has been removed from the input pulley belt and sufficient slack in the belt so that it may be removed from the pulleys 7 Remove the generator and drive input pulley belts from the step up pulley 8 Remove the snap ring that secures the step up pulley t...

Page 174: ...ibution Prohibited by Law Page 174 11 Adjust the Input and Generator pulley tension Go to Inspecting and Adjusting the Generator Belt Tension procedure FIGURE 157 STEP UP PULLEY 12 Tighten the two step up input pulley mounting bolts Torque to 160 inch pounds ...

Page 175: ... then recheck the belt tension FIGURE 158 GENERATOR 18 The drive input belt tension should read approximately 120 10 lbs and the generator belt tension should read approximately 90 10 lbs See Drive Belt Gauge Instructions on page 265 for attaining maximum accuracy from the gauge 19 Lift the stairarms and thread the flat belts through the pulleys 20 Replace the covers as per procedure Cover Replace...

Page 176: ...olt insert a socket extension about twelve inches long or equivalent in the drive input housing cavity just below the crank arm to prevent rotation and torque the mounting bolt to 300 inch pounds or 25 foot pounds Note The position of the flat belt pulley on the crank arm and the flat belt pulley on the input pulley When the crank arm is replaced the flat belt pulleys must be positioned so that th...

Page 177: ...p ring Make sure the snap ring is fully seated into the shaft groove FIGURE 161 CRANK ARM FLAT BELT PULLEY Note The position of the flat belt pulley on the crank arm and the flat belt pulley on the input pulley When the crank arm is replaced the flat belt pulleys must be positioned so that they are 180 degrees opposing 6 Replace the covers as per procedure Cover Replacement on page 53 ...

Page 178: ...ion from the inner flat belt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down FIGURE 162 GENERATOR 3 Loosen the two bolts that secure the step up pulley mounting bracket bolts to the frame 4 Loosen the adjustment bolt for the step up pulley until tension has been removed from the input pulley belt and it can be remove...

Page 179: ...oduction and Distribution Prohibited by Law Page 179 FIGURE 163 STEP UP PULLEY 5 Remove the snap ring from the flat belt pulley shaft located on the drive input pulley Remove the pulley and wave washer FIGURE 164 CRANK ARM FLAT BELT PULLEY ...

Page 180: ...sert a socket extension about twelve inches long or equivalent in the drive input housing cavity just below the crank arm to prevent rotation Remove the crank arm bolt washer and crank arm It may be necessary to use a Pitman arm puller or a 4 to 6 inch gear puller to remove the crank arm Do not use a hammer or mallet to remove the crank arm FIGURE 165 CRANK ARM BOLT REMOVAL INSTALLATION ...

Page 181: ...uare washer that secures the drive input pulley assembly to the drive input housing Pull the drive input pulley out of the housing Note If necessary a rubber mallet can be used to dislodge the input pulley assembly from the housing by tapping on the input shaft from the crank arm side FIGURE 166 DRIVE INPUT ASSEMBLY ...

Page 182: ...d square washer Make sure that the square washer does not contact the drive input pulley after installation test by spinning the drive input pulley through its full range FIGURE 167 DRIVE INPUT ASSEMBLY ALIGNMENT 11 Replace the drive input belt over the drive input pulley and the step up pulley 12 Place the crank arm on the shaft and secure the crank arm with mounting bolt and washer To tighten th...

Page 183: ...ion and torque the mounting bolt to 300 inch pounds or 25 foot pounds Note The position of the flat belt pulley on the crank arm and the flat belt pulley on the input pulley When the crank arm is replaced the flat belt pulleys must be positioned so that they are 180 degrees opposing FIGURE 168 CRANK ARM ALIGNMENT FIGURE 169 CRANK ARM BOLT REMOVAL INSTALLATION ...

Page 184: ...ully seated into the shaft groove 14 Adjust the Input and Generator pulley tension Go to Inspecting and Adjusting the Generator Belt Tension procedure 15 Lift the stairarms and then thread the flat belts over the flat belt pulleys 16 Select the QUICKSTART program and adjust the resistance up key until resistance level 10 is displayed Pedal the AMT for approximately one minute and then recheck the ...

Page 185: ...per procedure Cover Replacement on page 53 Replacing the Lift Arm Housing Lift Arm Housing Replacement Procedure 1 Remove the covers as per procedure Cover Replacement on page 53 2 Remove the tension from the inner flat belt pulleys by lifting up on the stairarms pulling the flat belts off the flat belt pulleys and then gently setting the stairarm down Gas Shock Removal 3 Release tension from the ...

Page 186: ... upper mounting stud 5 Rotate the gas shock down and out of the way of the incline motor FIGURE 171 GAS SHOCK 6 Using needle nosed pliers pull the retaining clip off the lower gas mounting stud and remove shock Incline Motor Removal 7 Remove the hitch pin from the Incline motor mounting pin 8 Remove the Incline motor mounting pin If the Incline is jammed or has excessive pressure on the pin it may...

Page 187: ...the snap ring from the flat belt pulley shaft located next to the Incline motor Remove the pulley and wave washer Removing the flat belt pulley will allow access to the Incline motor mounting bolt 10 Remove the Incline motor mounting bolt and remove the Incline motor FIGURE 173 INCLINE MOTOR MOUNTING ...

Page 188: ...12 To loosen the crank arm mounting bolt insert a socket extension about twelve inches long or equivalent in the drive input housing cavity just below the crank arm to prevent rotation Remove the crank arm bolt washer and crank arm It may be necessary to use a Pitman arm puller or a 4 to 6 inch gear puller to remove the crank arm Do not use a hammer or mallet to remove the crank arm ...

Page 189: ...d Distribution Prohibited by Law Page 189 FIGURE 175 CRANK ARM BOLT REMOVAL INSTALLATION 13 Remove the snap ring from the flat pulley shaft located on to the drive input pulley remove the pulley and wave washer FIGURE 176 DRIVE INPUT FLAT BELT PULLEY ...

Page 190: ...her that secures the drive input pulley assembly to the drive input housing Pull the drive input pulley out of the housing Note If necessary a rubber mallet can be used to dislodge the input pulley assembly from the housing by tapping on the input shaft FIGURE 177 DRIVE INPUT ASSEMBLY FIGURE 178 DRIVE INPUT ASSEMBLY ALIGNMENT ...

Page 191: ...ing bolts and washers that secure the flat belt clamps to the Lift Arm FIGURE 179 LIFT ARM AND BELT CLAMPS 16 Remove the five mounting bolts that secure the left and right side arm housings to the input housing FIGURE 180 LIFT ARM MOUNTING BOLTS 17 Separate the left and right side arm housings from the input housing ...

Page 192: ...mounting bolts torque the bolts to 160 inch pounds 19 Install the drive input assembly by aligning the bearing snap ring opening with tab of the drive input housing 20 Fasten the drive input assembly to the drive input housing using the screw and square washer Make sure that the square washer does not contact the drive input pulley after installation test by spinning the drive input pulley through...

Page 193: ...olt insert a socket extension about twelve inches long or equivalent in the drive input housing cavity just below the crank arm to prevent rotation Remove the crank arm bolt washer and crank arm Torque the mounting bolt to 300 inch pounds or 25 foot pounds Note The position of the flat belt pulley on the crank arm and the flat belt pulley on the input pulley When the crank arm is replaced the flat...

Page 194: ...Distribution Prohibited by Law Page 194 23 Install the crank arm pinch bolt washer and lock nut Torque the pinch bolt and lock nut to 300 inch pounds or 25 foot pounds FIGURE 184 CRANK ARM BOLT REMOVAL INSTALLATION FIGURE 185 CRANK ARM FLAT BELT PULLEY ...

Page 195: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 195 24 Place a belt gauge on the drive input belt as shown below FIGURE 186 DIVE INPUT BELT ...

Page 196: ...ximately 120 10 lbs If the belt tension is significantly high or low the belt tension may be adjusted by following the steps below See Drive Belt Gauge Instructions on page 265 26 Loosen or tighten the step up pulley adjustment bolt until the belt gauge reads approximately 160 lbs See Drive Belt Gauge Instructions on page 265 ...

Page 197: ...ized Reproduction and Distribution Prohibited by Law Page 197 FIGURE 187 STEP UP PULLEY 27 Tighten the two step up input pulley mounting bolts Torque to 160 inch pounds 28 Place a belt gauge on the generator belt as shown in below ...

Page 198: ...d by loosening or tightening the generator mounting adjustment bolt See Drive Belt Gauge Instructions on page 265 30 Loosen or tighten the generator adjustment nut and bolt until the belt gauge reads approximately 90 lbs See Drive Belt Gauge Instructions on page 265 31 Tighten the two bolts that secure the generator mounting bracket to the frame Torque to 160 inch pounds 32 Lift the stairarms and ...

Page 199: ...layed Pedal the AMT for approximately one minute then recheck the belt tension FIGURE 189 GENERATOR 34 The drive input belt tension should read approximately 120 10 lbs and the generator belt tension should read approximately 90 10 lbs See Drive Belt Gauge Instructions on page 265 Incline Motor Installation 35 Attach the replacement Incline motor to the frame using the 3 8 16 mounting bolt ...

Page 200: ...0 Settings on page Error Bookmark not defined 38 With the lift incline number displayed set the incline to level 2 using the STRIDE HEIGHT up and STRIDE HEIGHT down keys 39 Rotate the incline motor tube on the incline motor drive screw until the measurement between the top of the incline nut and the end of the incline motor drive screw is 1 1 4 inches Note When rotating the incline motor tube do n...

Page 201: ...EMENT Gas Shock Installation 40 Rotate the gas shock up 41 Adjust the height of the gas shock by lowering or raising the front of the Incline platform until the gas shock and the upper mounting stud align 42 Press the gas shock onto the mounting stud and secure the gas shock to the upper mounting stud by pushing in on the tension clip ...

Page 202: ... wave washer and flat belt pulley secure the flat belt pulley with the snap ring 46 Secure the flat belt clamps to the lift arm housing using the four 3 8 16 X 3 mounting bolts and washers 47 Lift the stairarms and thread the flat belts through the pulleys 48 Replace the covers as per procedure Cover Replacement on page 53 Replacing the drive input housing Drive Input Housing Replacement Procedure...

Page 203: ... Law Page 203 3 Loosen the two bolts that secure the step up pulley mounting bracket bolts to the frame 4 Loosen the adjustment bolt for the step up pulley until tension has been removed from the input pulley belt and it can be removed from the pulleys FIGURE 194 STEP UP PULLEY ...

Page 204: ...ely remove the retaining clip as it is difficult to reinstall Tip If the incline motor is jammed at full elevation remove the lower retaining clip to facilitate the gas shock removal 6 Using another flat head screw driver as a pry bar place the screw driver head between the frame and the top of the gas shock and pry the shock off the upper mounting stud 7 Rotate the gas shock down and out of the w...

Page 205: ... stud and remove shock Motor Removal 9 Remove the hitch pin from the Incline motor mounting pin 10 Remove the Incline motor mounting pin If the Incline is jammed or has excessive pressure on the pin it may be necessary to drive the pin out of the Incline motor tube and Incline platform using a punch and rubber mallet FIGURE 196 INCLINE MOTOR HITCH PIN AND MOUNTING PIN ...

Page 206: ... the snap ring from the flat belt pulley shaft located next to the Incline motor Remove the pulley and wave washer Removing the flat belt pulley will allow access to the Incline motor mounting bolt 12 Remove the Incline motor mounting bolt and remove the Incline motor FIGURE 197 INCLINE MOTOR MOUNTING ...

Page 207: ...14 To loosen the crank arm mounting bolt insert a socket extension about twelve inches long or equivalent in the drive input housing cavity just below the crank arm to prevent rotation Remove the crank arm bolt washer and crank arm It may be necessary to use a Pitman arm puller or a 4 to 6 inch gear puller to remove the crank arm Do not use a hammer or mallet to remove the crank arm ...

Page 208: ...d Distribution Prohibited by Law Page 208 FIGURE 199 CRANK ARM BOLT REMOVAL INSTALLATION 15 Remove the snap ring from the flat pulley shaft located on to the drive input pulley remove the pulley and wave washer FIGURE 200 DRIVE INPUT FLAT BELT PULLEY ...

Page 209: ...he drive input housing Pull the drive input pulley out of the housing Note If necessary a rubber mallet can be used to dislodge the input pulley assembly from the housing by tapping on the input shaft FIGURE 201 DRIVE INPUT ASSEMBLY FIGURE 202 DRIVE INPUT ASSEMBLY ALIGNMENT 17 Remove the four 3 8 16 X 3 mounting bolts and washers that secure the flat belt clamps to the Lift Arm ...

Page 210: ...03 LIFT ARM AND BELT CLAMPS 18 Remove the five 5 16 18X1 mounting bolts that secure the left and right side arm housings to the input housing FIGURE 204 LIFT ARM MOUNTING BOLTS 19 Separate the left and right side arm housings from the input housing FIGURE 205 LIFT ARM HOUSING AND DRIVE INPUT HOUSING ...

Page 211: ...ing bolts that secure the drive input housing to the frame FIGURE 206 LIFT ARM HOUSING AND DRIVE INPUT HOUSING 21 Fasten the replacement drive input housing to the frame using the four mounting bolts removed in step 9 torque to 160 inch pounds Note Ensure the drive input alignment tab is position to the left side ...

Page 212: ... five 5 16 18X1 mounting bolts FIGURE 208 LIFT ARM MOUNTING BOLTS 23 Install the drive input assembly by aligning the bearing snap ring opening with tab of the drive input housing 24 Fasten the drive input assembly to the drive input housing using the screw and square washer Make sure that the square washer does not contact the drive input pulley after installation test by spinning the drive input...

Page 213: ... crank arm mounting bolt insert a socket extension about twelve inches long or equivalent in the drive input housing cavity just below the crank arm to prevent rotation Remove the crank arm bolt washer and crank arm Torque the mounting bolt to 300 inch pounds or 25 foot pounds Note The position of the flat belt pulley on the crank arm and the flat belt pulley on the input pulley When the crank arm...

Page 214: ... and lock nut Torque the pinch bolt and lock nut to 300 inch pounds or 25 foot pounds FIGURE 211 CRANK ARM BOLT REMOVAL INSTALLATION 28 Replace the wave washer and flat belt pulley onto the crank arm shaft and secure with the snap ring Make sure the snap ring is fully seated into the shaft groove FIGURE 212 CRANK ARM FLAT BELT PULLEY ...

Page 215: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 215 29 Place a belt gauge on the drive input belt as shown below FIGURE 213 DIVE INPUT BELT ...

Page 216: ...10 lbs If the belt tension is significantly high or low the belt tension may be adjusted by following the steps below See Drive Belt Gauge Instructions on page 265 31 Loosen or tighten the step up pulley adjustment bolt until the belt gauge reads approximately 160 lbs See Drive Belt Gauge Instructions on page 265 FIGURE 214 STEP UP PULLEY ...

Page 217: ...stribution Prohibited by Law Page 217 32 Tighten the two step up input pulley mounting bolts Torque to 160 inch pounds 33 Install the generator belt over the step up pulley and generator pulley 34 Place a belt gauge on the generator belt as shown in below ...

Page 218: ...d by loosening or tightening the generator mounting adjustment bolt See Drive Belt Gauge Instructions on page 265 36 Loosen or tighten the generator adjustment nut and bolt until the belt gauge reads approximately 90 lbs See Drive Belt Gauge Instructions on page 265 37 Tighten the two bolts that secure the generator mounting bracket to the frame Torque to 160 inch pounds 38 Lift the stairarms and ...

Page 219: ...layed Pedal the AMT for approximately one minute and then recheck the belt tension FIGURE 216 GENERATOR 40 The drive input belt tension should read approximately 120 10 lbs and the generator belt tension should read approximately 90 10 lbs See Drive Belt Gauge Instructions on page 265 41 Attach the Incline motor to the frame using the 3 8 16 mounting bolt FIGURE 217 INCLINE MOTOR MOUNTING ...

Page 220: ...defined 44 With the lift incline number displayed set the incline to level 2 using the STRIDE HEIGHT and STRIDE HEIGHT keys 45 Rotate the incline motor tube on the incline motor drive screw until the measurement between the top of the incline nut and the end of the incline motor drive screw is 1 1 4 inches Note When rotating the incline motor tube do not allow the incline motor drive screw to rota...

Page 221: ...ate the gas shock up 47 Adjust the height of the gas shock by lowering or raising the front of the Incline platform until the gas shock and the upper mounting stud align 48 Press the gas shock onto the mounting stud and secure the gas shock to the upper mounting stud by pushing in on the tension clip FIGURE 219 GAS SHOCK ...

Page 222: ...through the pulleys 53 Replace the covers as per procedure Cover Replacement on page 53 Replacing a Tie Rod Procedure 1 Remove the covers as described per procedure Cover Replacement on page 53 2 Remove the tie rod mounting bolt and washer that secures the lower tie rod end to the cam assembly 3 Remove the tie rod mounting bolt and washer that secures the upper tie rod end to the upper arm axle 4 ...

Page 223: ...nsor Procedure 1 Remove the covers as described per procedure Cover Replacement on page 53 Stride Dial Removal 2 Disconnect the stride dial cable connector from the stride dial PCA 3 Remove the two screws that secure the stride bracket to the frame and then remove the stride dial assembly FIGURE 221 STRIDE DIAL ASSEMBLY ...

Page 224: ...not fully tighten the screws 5 Adjust the stride dial bracket until the stride dial target is centered between the two stride sensors on the stride dial PCA 6 Fully tight in the two screws that secure the stride dial sensor to the frame 7 Reconnect the stride dial cable connector to the stride dial sensor ensure the cable is routed and secured away from the H Brake cam stops FIGURE 222 STRIDE DIAL...

Page 225: ...Unauthorized Reproduction and Distribution Prohibited by Law Page 225 8 Replace the covers as described per procedure Cover Replacement on page 53 Replacing the H Brake Belt FIGURE 223 H BRAKE BELT AND H BRAKE CAM Procedure ...

Page 226: ...towards the right and remove H Brake Belt Installation 5 Apply a thin layer of AMSOIL GPOR1 synthetic polymeric grease along the cam clamp track 6 Position one of the belt clamps over the cam so that the length of the belt is hanging down the left side of the AMT and then slide the clamp onto the cam from right to left until clamp hits the stop 7 Feed the belt through the frame and under the H bra...

Page 227: ...ould read approximately 110 120 lbs If the belt tension is significantly high or low the belt tension may be adjusted by loosening or tightening the H Brake adjustment bolt 11 Replace the covers per procedure Cover Replacement on page 53 Replacing the H Brake Cam Assembly FIGURE 226 H BRAKE BELT AND H BRAKE CAM ...

Page 228: ...ion and Distribution Prohibited by Law Page 228 Procedure 1 Remove the covers as described per procedure Cover Replacement on page 53 H Brake Belt Removal 2 Remove the H Brake tension bolt the two washers and nut FIGURE 227 H BRAKE BELT ASSEMBLY ...

Page 229: ...the clamp under the cam and out to the left side of the AMT 4 Slide the left side belt clamp off the cam towards the right and remove Stride Dial Removal 5 Disconnect the stride dial cable connector from the stride dial PCA 6 Remove the two screws that secure the stride bracket to the frame and then remove the stride dial assembly FIGURE 228 STRIDE DIAL ASSEMBLY ...

Page 230: ...w Page 230 Tie Rod Removal 7 Remove the tie rod mounting bolts and washers that secure each lower tie rod end to the cam assembly FIGURE 229 TIE RODS H Brake Cam Removal and Installation 8 Remove the bolt and washer that secures the cam assembly to the frame FIGURE 230 CAM ASSEMBLY ...

Page 231: ... inch pounds FIGURE 231 TIE RODS Stride Dial Assembly Installation 11 Secure the stride dial assembly to the frame with the two screws do not fully tighten the screws 12 Adjust the stride dial bracket unit the stride dial target is centered between the two stride sensors on the stride dial PCA 13 Fully tight in the two screws that secure the stride dial sensor to the frame 14 Reconnect the stride ...

Page 232: ...16 Position one of the belt clamps over the cam so that the length of the belt is hanging down the left side of the AMT and then slide the clamp onto the cam from right to left until clamp hits the stop 17 Feed the belt through the frame and under the H brake pulley 18 Slide the clamp onto the cam and fasten the clamps together using the H Brake tension bolt washers and nut H Brake Belt Tensioning...

Page 233: ...pproximately 110 120 lbs If the belt tension is significantly high or low the belt tension may be adjusted by loosening or tightening the H Brake adjustment bolt 21 Replace the covers as described per procedure Cover Replacement on page 53 Replacing the H Brake Drum Assembly Procedure 1 Remove the covers as described per procedure Cover Replacement on page 53 ...

Page 234: ...remove Gas Shock Removal 5 Release tension from the top of the gas shock by pushing a 1 flat top screw driver in the slot under the tension clip Do not completely remove the retaining clip as it is difficult to reinstall Tip If the incline motor is jammed at full elevation remove the lower retaining clip to facilitate the gas shock removal 6 Using another flat head screw driver as a pry bar place ...

Page 235: ...d and remove shock Incline Motor Removal 9 Remove the hitch pin from the Incline motor mounting pin 10 Remove the Incline motor mounting pin If the Incline is jammed or has excessive pressure on the pin it may be necessary to drive the pin out of the Incline motor tube and Incline platform using a punch and rubber mallet FIGURE 236 INCLINE MOTOR HITCH PIN AND MOUNTING PIN ...

Page 236: ...nd Distribution Prohibited by Law Page 236 11 Remove the snap ring from the flat belt pulley shaft located next to the Incline motor Remove the pulley and wave washer Removing the flat belt pulley will allow access to the Incline motor mounting bolt ...

Page 237: ...installation of the H Brake Drum for both configuration H Brake Drum Removal and Installation Units Built Prior to 10 1 2012 13 Remove the screw that secures the H Brake drum assembly to the 90 degree bracket mounted on the frame 14 Remove the 5 16 18 X 4 bolt and washer that secure the H Brake assembly drum to the frame and then remove the H Brake drum assembly 15 Hand Tighten the replacement H B...

Page 238: ...ssed inside the H Brake Drum through the round cut out 19 Remove the screw that secures the H Brake drum assembly to the frame 20 Remove the 5 16 18 X 4 bolt and washer that secure the H Brake assembly drum to the frame and then remove the H Brake drum assembly 21 Hand tighten the replacement H Brake assembly to the frame using the 5 16 18 X 4 bolt and washer removed in the previous step 22 Fasten...

Page 239: ...T AFTER 10 1 1012 Incline Motor Installation 1 Attach the replacement Incline motor to the frame using the 3 8 16 mounting bolt FIGURE 240 INCLINE MOTOR MOUNTING 2 Connect the incline motor cable connector to the lower PCA and replace the lower PCA cover as per procedure Replacing the Lower PCA and Battery Bracket on page 164 ...

Page 240: ...t and the end of the incline motor drive screw is 1 1 4 inches Note When rotating the incline motor tube do not allow the incline motor drive screw to rotate If the incline motor drive screw rotates the lift level number will change The lift level number must be 2 and the physical measurement must be 1 1 4 inches for the calibration to be correct FIGURE 241 INCLINE MOTOR CALIBRATION MEASUREMENT Ga...

Page 241: ...eplace the wave washer and flat belt pulley secure the flat belt pulley with the snap ring H Brake Belt Installation 12 Apply a thin layer of AMSOIL GPOR1 synthetic polymeric grease along the cam clamp track 13 Position one of the belt clamps over the cam so that the length of the belt is hanging down the left side of the AMT and then slide the clamp onto the cam from right to left until clamp hit...

Page 242: ...read approximately 110 120 lbs If the belt tension is significantly high or low the belt tension may be adjusted by loosening or tightening the H Brake adjustment bolt 18 Replace the covers as described per procedure Cover Replacement on page 53 Replacing the Gas Shock Replacing the Gas Shock 1 Remove the covers per procedure Cover Replacement on page 53 ...

Page 243: ...ck removal 4 Using another flat head screw driver as a pry bar place the screw driver head between the frame and the top of the gas shock and pry the shock off the upper mounting stud 5 Rotate the gas shock down and out of the way of the incline motor FIGURE 244 GAS SHOCK Disconnecting the Incline Motor 6 Remove the hitch pin from the Incline motor mounting pin 7 Remove the Incline motor mounting ...

Page 244: ...nd the upper mounting stud align 10 Press the gas shock onto the mounting stud and secure the gas shock to the upper mounting stud by pushing in on the tension clip Caution It is recommended to have assistance available for the following step s 11 With the assistance lift the front of the Incline platform until the Incline tube mounting holes align with the Incline platform mounting holes 12 Repla...

Page 245: ...vement 5 Disconnect the incline motor cable connector from the lower PCA and detach the cable from the lower PCA battery bracket cable retainer Remove the cable from the frame attachment cable clips 6 Remove the incline motor actuator tube from the lift platform mounting bracket Remove the clevis and hitch pin The gas shock is under compression pushing the lift platform down to the level 1 positio...

Page 246: ...line motor remove the pulley and wave washer Removing the flat pulley will allow access to the Incline motor upper mounting bolt FIGURE 247 INCLINE MOTOR FLAT BELT PULLEY 8 Remove the incline motor housing mount bolt and remove the Incline motor Early model AMTs used a bolt with bushing installation hardware later models used a larger diameter bolt illuminating the need ...

Page 247: ...ch to frame cable clamps and connect to the lower PCA Replace the lower PCA cover 12 Reinstall the belt keeper bracket 13 Reinstall the left and right flat belts 14 Access the Hardware Validation diagnostics select CROSSRAMP and set the cross ramp to level 1 This sets the lift motor to the correct calibration position and holds the cross ramp at level 1 CAUTION The cross ramp must be set to level ...

Page 248: ... the lift actuator tube so that the lift actuator tube and lift platform bracket mounting holes align Insert the clevis pin and secure with the hitch pin 19 Remove the painters tape from the gas spring shaft 20 Clear the lift motor platform area from any obstructions shims blocks etc that can interfere with the lift system up down movement 21 Reinstall the left right flat belts 22 Access the CROSS...

Page 249: ...n specification Readjust if necessary b If greater than 3 4 inch set Cross Ramp to level 1 and readjust the lift motor actuator tube to decrease the mounting distance Remove the lift motor mounting pin rotate the lift motor actuator tube turn clockwise manually raise the lift platform to align the mounting holes and reinstall the hitch pin Verify that the incline level 5 A D value is within specif...

Page 250: ......

Page 251: ...Belt Gauge Instructions Measuring the Resistance of a Generator Caution If an external power supply is connected to the AMT disconnect the external power supply from the AMT before continuing with this procedure Procedure 1 Remove the right side cover as per Procedure Cover Replacement on page 53 2 Remove the positive battery wire from the lower PCA FIGURE 249 BATTERY WARNING Before continuing wit...

Page 252: ...ck wires Each reading should be approximately 25 Ω Ohms Reconnect the wires removed in step 6 8 If the readings are still incorrect replace the three phase generator 9 Reconnect the red battery wire removed in step 3 10 Replace the right side cover as per Cover Replacement on page 53 Inspecting and Adjusting the H brake Belt Tension WARNING Before continuing with this procedure review the Warning ...

Page 253: ...ion Prohibited by Law Page 253 3 The belt gauge should read approximately 110 120 lbs If the belt tension is significantly high or low the belt tension may be adjusted by loosening or tightening the H Brake adjustment bolt FIGURE 251 H BRAKE BELT AND H BRAKE CAM ...

Page 254: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 254 ...

Page 255: ... with this procedure review the Warning and Caution statements listed in the Warning and Caution Statements and General Safety Guidelines Section Things You Should Know Procedure 1 Remove the gasket top front rear left and right side covers per procedure Cover Replacement on page 53 2 Place a belt gauge on the generator belt as shown in below FIGURE 252 GENERATOR BELT ...

Page 256: ...sed 60 75 lbs 27 2 34 kgs Note More than 1 hour of use 4 Loosen or tighten the generator adjustment nut and bolt until the belt gauge reads approximately 90 lbs 5 Tighten the generator mounting bolts 6 Select the QUICKSTART program and adjust the resistance up key until resistance level 10 is displayed Pedal the AMT for approximately one minute and then recheck the belt tension 7 Recheck the drive...

Page 257: ...g with this procedure review the Warning and Caution statements listed in the Warning and Caution Statements and General Safety Guidelines Section Things You Should Know Procedure 1 Remove the gasket top front rear left and right side covers per Cover Replacement on page 53 Procedure 2 Place a belt gauge to the drive input belt as shown below FIGURE 254 DIVE INPUT BELT ...

Page 258: ...within specification continue with the following adjustment steps See Drive Belt Gauge Instructions Drive Belt Tension Specification Drive Belt Tension new 135 5 lbs 61 2 2 3 kgs used 100 125 lbs 45 4 56 7 kgs Note More than 1 hour of use 4 Loosen the generator mounting bolts 5 Loosen the generator adjustment bolt FIGURE 255 GENERATOR ...

Page 259: ... Reproduction and Distribution Prohibited by Law Page 259 6 Loosen the two step up pulley mounting bolts 7 Loosen or tighten the step up pulley adjustment bolt until the belt gauge reads approximately 160 lbs FIGURE 256 STEP UP PULLEY ...

Page 260: ... bolts 9 Select the QUICKSTART program and adjust the resistance key until resistance level 10 is displayed Pedal the AMT for approximately one minute then recheck the belt tension 10 Recheck the drive belt tension readjust if needed 11 Place a belt gauge on the generator belt as shown in below FIGURE 257 GENERATOR BELT ...

Page 261: ...fication continue with the following adjustment steps See Drive Belt Gauge Instructions Generator Belt Tension Specification Generator Belt Tension new 85 5 lbs 38 6 2 3 kgs used 60 75 lbs 27 2 34 kgs Note More than 1 hour of use 13 Loosen or tighten the 1 4 20 X 3 generator adjustment nut and bolt until the belt gauge reads approximately 90 lbs ...

Page 262: ... bolts 15 Select the QUICKSTART program and adjust the resistance key until resistance level 10 is displayed Pedal the AMT for approximately one minute and then recheck the belt tension 16 Recheck the generator belt tension readjust if out of spec FIGURE 258 GENERATOR 17 Replace the main covers as per procedure Cover Replacement on page 53 ...

Page 263: ...ront side and rear covers 3 Access the Hardware Validation diagnostics select CROSSRAMP and set the cross ramp to level 1 This sets the lift motor to the correct calibration position and holds the cross ramp at level 1 Important Make sure to set the incline level to 1 fully extended gas spring before starting this procedure 4 Lift up on the stair arms while removing the left and right flat belts o...

Page 264: ...ching the lift motor to the platform 8 Rotate and adjust the lift actuator tube so that the lift actuator tube and lift platform bracket mounting holes align Insert the clevis pin and secure with the hitch pin 9 Grasp and attempt to move the lift motor to make sure the upper frame weldment mount is a snug fit very little connection play If loose make sure that the correct mounting bolt or bolt bus...

Page 265: ... turn clockwise manually raise the lift platform to align the mounting holes and reinstall the hitch pin Verify that the incline level 5 A D value is within specification Readjust if necessary 17 Set the Cross Ramp to level 1 Verify the A D value is between 38 and 42 18 Operate the incline through its entire range to ensure proper operation 19 Reinstall the front side and rear covers 20 Verify AMT...

Page 266: ...ercome this once the gauge is in place on the belt tap on the back of the gauge with a small hand tool screwdriver wrench etc 5 8 times before reading 3 Read tension on the dial face across from the indicator on the gauge body 4 If the belt tension is within manufacture s specifications seat the belt Run the machine for approximately 1 2 minutes and then re check the tension This will allow the be...

Page 267: ...s Foot Pedals using a 30 1 diluted solution of Simple Green and water Do not use acidic cleaners Weekly All of the above plus 1 Clean the Frame covers handle bars stairarms Foot Pedals with water or 30 1 diluted solution of Simple Green and water Do not use acidic cleaners 2 Vacuum carpet or damp mop the floor underneath the AMT 3 Check unit leveling and re adjust if necessary Monthly All of the a...

Page 268: ...r Wipe down stairarms using a 30 1 diluted solution of Simple Green and water Wipe down foot pedals using a 30 1 diluted solution of Simple Green and water Vacuum carpet or damp mop the floor underneath the AMT Check unit leveling and adjust if necessary To Be Done Monthly Wipe down unit covers using a 30 1 diluted solution of Simple Green and water Wipe down handlebars using a 30 1 diluted soluti...

Page 269: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 269 9 Wiring Block Diagrams P30 AMT 11 835 Block Diagram P20_P30_P80 AMT 11 Wiring Diagram ...

Page 270: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 270 ...

Page 271: ...rporated Unauthorized Reproduction and Distribution Prohibited by Law Page 271 10 Exploded View The Exploded View is included as a quick reference Refer to the Precor Connect website for the most recent information ...

Page 272: ... Precor Incorporated Unauthorized Reproduction and Distribution Prohibited by Law Page 272 ...

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Precor AMT12 base, Service Manual

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Summary of Contents for AMT12 base

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