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C776i Stairclimber

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Section One - Things You Should Know

About This Manual

This manual is written for you, the C760 Series Climber service technician. The objective of this
service manual is to provide you with the instructions you need to maintain, inspect and adjust
C760 Series Climbers, troubleshoot malfunctions, and remove and replace components. This
manual includes the sections and appendices described in the following paragraphs.

Section One, Things You Should Know.

This section includes warning and caution statements,

safety guidelines, and a list of required tools and equipment. It is highly recommended that you
read this section, as well as the C776i Climber Owner’s Manual, before performing the
maintenance procedures provided in this manual.

Section Two, Software Features.

The C776i Climbers are programmed with several diagnostic

and setup features. This section contains the procedures you need to access these features.

Section Three, Preventive Maintenance.

This section provides regular (scheduled)

maintenance activities that should be performed to keep the C776i Climbers in peak condition.

Section Four, Checking Unit Operation.

This procedure provides you with a quick way of

checking the climber operation. Check the climber operation at the end of a maintenance
procedure and when it is necessary to ensure that the climber is operating properly.

Section Five, Inspection and Adjustment Procedures.

Perform inspection procedures when a

trouble symptom points to a particular problem and after removing and replacing major
components. Many maintenance problems can be fixed by adjusting various climber
components. This section provides you with the step-by-step procedures required to make these
adjustments.

Section Six, Troubleshooting Procedures.

The diagnostic and troubleshooting procedures

contained in this section should be performed when it is necessary to isolate a problem to a
particular component.

Section Seven, Replacement Procedures.

When a C776i Climber component must be

replaced, go to this section and follow the step by step instructions required to remove and
replace the malfunctioning component.

General Information

For the latest exploded view, part number and part pricing information, visit the Precor dealer
website at “www.precor.com/connection”.

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Summary of Contents for C776i

Page 1: ...n this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures troubleshooting procedures replacement procedures and electrical block and wiring diagrams To move directly to a procedure click the appropriate procedure in the bookmark section to the left of this page You may dra...

Page 2: ...t should be performed to keep the C776i Climbers in peak condition Section Four Checking Unit Operation This procedure provides you with a quick way of checking the climber operation Check the climber operation at the end of a maintenance procedure and when it is necessary to ensure that the climber is operating properly Section Five Inspection and Adjustment Procedures Perform inspection procedur...

Page 3: ...nsitive devices Wrist straps dissipate static before it can damage static sensitive devices you are servicing Follow anti static handling procedures and wear an anti static device such as a wrist strap when you perform this procedure Wrist straps are made for static control They will neither reduce or increase the risk of electrical shock when using or working on electrical equipment When you wear...

Page 4: ...w the magnet to cool by removing power from the climber and waiting four hours with the covers off before you perform maintenance operations or operate the climber If the user s heart rate has reached or exceeded the maximum heart rate The user MUST consult a physician before operating the C760 Series Climber Caution statements are intended to prevent damage to the C760 Series Climber as a result ...

Page 5: ...C776i Stairclimber Page 5 Keep all electrical components such as the power cord and the ON OFF switch away from water and other liquids ...

Page 6: ...able when you service C760 Series Climbers TOOLS EQUIPMENT 2 phillips screwdriver anti static wrist strap 2 flat head screwdriver ohmmeter voltmeter 1 8 5 32 and 3 16 allen wrenches blue loctite 3 8 7 16 1 2 2 3 4 and 17mm 2 cable ties open end wrenches damp cloth mild detergent 1 2 drive socket wrench set tape chip puller feeler gauge 0 030 feeler gauge 0 050 needle nose pliers pliers snap ring p...

Page 7: ... in the powered up condition unless the climber is equipped with an optional external power supply 1 With the climber powered up press keys RESET 6 5 sequentially Diagram 2 1 C776i Console 2 The message INFORMATION DISPLAY will be displayed for two seconds and then ODOMETER for two seconds The total number of floors climbed will be displayed as XXX FLOORS Press the ENTER key to continue to the tot...

Page 8: ... occurred For example 1 ER05 123456 FLR 45678 HRS The error log can record up to ten error conditions The error code in position one will be the most recent error and the error in position ten will be the oldest error If more than ten errors have been logged only the ten most recent will be displayed When a new error is logged the oldest error will be deleted from the log Use the T and S keys to m...

Page 9: ...YBOARD TEST will be displayed followed by a graphical representation of each key position on the display housing As each key on the display is pressed the key representation is turned off indicating that the key is functioning Check each key in this manner including the numeric keyboard Press and hold the ENTER key for 2 seconds to advance to the heart rate test 5 The message HEART RATE TEST will ...

Page 10: ...age 10 8 The message BRAKE TEST will be displayed followed the power bit reading and SPM reading This test allows you to test the brake resistance at each step rate level Press the ENTER key to exit the diagnostics program ...

Page 11: ...ME will be displayed followed by the currently selected maximum workout time Use the T and S keys to select the maximum workout time The maximum workout time may be set between 1 and 240 minutes or no limit Press ENTER to advance to maximum pause time 5 The message SET MAX PAUSE TIME will be displayed followed by the currently selected maximum pause time Use the T and S keys to select the maximum ...

Page 12: ...oblem occurs record the following information Model and serial number Software version number Note Determine the version number of the PROM mounted on the upper PCA as described in Procedure 2 1 or by looking at the label on the PROM User and program number running when the problem occurred A description of a What happened or failed to happen b The action taken by the user just before the problem ...

Page 13: ...t be powered down before the upload procedure can be initiated Ensure that the EFX has not be used for a sufficient time to allow the lower PCA to completely discharge The light emitting diode on the lower PCA will go out when the power supply is discharged 2 If the CSAFE port is in use temporarily disconnect the RJ 45 cable from the CSAFE port If the CSAFE port is not in use temporarily remove th...

Page 14: ...g preventive maintenance schedule be followed At the End of Each Day Wipe down the stair arms and frame with a damp cloth Every Week Wipe the surface of the electronic console with a barely damp sponge or soft cloth Dry with a clean towel Vacuum underneath the climber following these steps a Turn off the climber with the circuit breaker then unplug the power cord from the wall outlet b Place the c...

Page 15: ... connections and replace wiring as necessary When the covers are removed visually inspect the lower ribbon cable and the part of the upper ribbon cable that is not inside the column If either ribbon cable is torn or damaged replace it as described in Procedure 7 XX Inspect the stairarm and drive belts If the belts show signs of wear or damage remove and replace the belts as described in either Pro...

Page 16: ... keys Verify that various information displays are functioning c Make sure that the stair arm belts do not rub on the cover 5 If you feel no resistance as you step if the climber makes unusual noises or the electronic display does not change appropriately THEN OTHERWISE Refer to Section XX Continue with the next step 6 Press the STEP RATE key until you reach Step Rate 60 60 steps per minute Operat...

Page 17: ...irclimber Page 17 THEN OTHERWISE Refer to Section XX Continue with the next step 10 Check the LED s mounted on the upper PCA and the function keys displayed on the electronic console by performing Procedure 2 2 ...

Page 18: ...cracks worn areas and missing teeth 5 If required replace the belt per Procedure 7 6 6 Wrap the stairarm belt over the HTD pulley behind and under the upper flanged pulley Wrap the belt under an around the lower flanged pulley Then lift the stairarm and hook the return spring on its mounting peg Check the belt to ensure there are no twists in the belt If there are remove the return spring from its...

Page 19: ...ee Diagram 7 7 Bend the tabs back into the locking position when the belt tension adjustments are complete 4 Changing the tension of the primary drive belt will affect the generator belt tension If the tension was primary drive belt tension was changed in step 3 continue with step 5 5 Place the belt tension gauge on the generator narrow belt as shown in Diagram 5 3 The belt gauge should read appro...

Page 20: ...C776i Stairclimber Page 20 Diagram 5 3 Generator Belt Tension Generator Mounting Bolt ...

Page 21: ...e 7 1 3 Disconnect the upper data cable from the mid point connector See Diagram 6 2 4 Connect a known good data cable from the upper printed circuit assembly to the mid point connector 5 If the C776i now functions correctly replace the upper data cable per Procedure XX If the C776i still functions incorrectly replace the original upper data cable and continue with step 6 Troubleshooting the Lower...

Page 22: ... mid point connector If the C776i still functions incorrectly replace the original mid point connector The problem may be caused by another component such as the upper printed circuit assembly or the lower printed circuit assembly Troubleshoot those component per the appropriate troubleshooting procedure 11 If all of the above test have been performed and the C776i is still not functioning correct...

Page 23: ...an ERROR 05 or STUCK KEY message is being displayed continue with step 3 Otherwise skip to step 7 3 Remove the four screws that fasten the display front panel to display housing 4 Disconnect the keyboard cable from the upper printed circuit assembly See Diagram 6 3 Diagram 6 3 Keyboard and Upper Printed Circuit Assembly 5 Use the C776i if the ERROR 05 or STUCK KEY message is still being displayed ...

Page 24: ...printed circuit assembly or the keyboard cable 8 The easiest means of determining which of the three components is the cause is the to replace them one at a time with a known good component 9 If all of the above test have been performed and the C776i is still not functioning correctly call Precor technical support ...

Page 25: ...bsent or significantly low continue with step 8 If the voltage measurements are now correct the cause is either the lower data cable upper data cable mid point connector or upper printed circuit assembly 5 Check the upper data cable lower data cable and mid point connector per Procedure 6 1 and if necessary replace the appropriate part 6 If the cables and mid point connector tested good in step 5 ...

Page 26: ...t 60 steps per minute See Diagram 6 4 9 If the voltage measurements are absent disconnect the three generator leads from the 3 PHASE GEN IN terminals and repeat the measurements in step 8 directly to the generator wires 10 If the voltage measurements are still absent replace the generator If the voltage measurements are now present replace the lower printed circuit assembly 11 If all of the above ...

Page 27: ...d connection terminals in any order 3 The following A C voltage readings will be measured on the 3 PHASE GEN IN terminals While the C776i is in use perform the same A C voltage reading between the red and black red and white and black and white wires All three voltage readings should be approximately 90 Vac at 60 steps per minute See Diagram 6 4 4 If the voltage measurements are present replace th...

Page 28: ...t strap receiver that is external of the heart rate PCA Note There are four typical failure modes for the hand held chest strap heart rate system They are hand held is normal no chest strap reading no hand held reading chest strap normal no hand held or chest strap reading constant or intermittent readings when neither hand held or chest strap are in use Diagram 6 5 Hand held chest strap heart rat...

Page 29: ...gated into two groups One group has blue shrink wrap around it and the other group has black shrink wrap around it The blue group must go to the right hand contacts and the black group must go to the left hand contacts In both groups the black wire must go to the lower contact and the red wire must go to the upper contact I necessary rewire the hand held contacts as described above and test as des...

Page 30: ...between the corresponding pins of J1 on the upper PCA red and black wires If 5 Vdc is not present replace the upper PCA If 5 Vdc is present replace the upper PCA to heart rate PCA cable Constant or intermittent readings when neither the hand held or chest strap is in use 13 Verify that a ferrite core is clamped around the heart rate PCA to upper PCA cable 14 Constant or intermittent heart rate rea...

Page 31: ...ear Cover Section Removal 6 Lowering one of the stairarms makes rear cover removal easier 7 The rear cover section is fastened with four screws two on top and two on the bottom 8 Remove the four cover screws and carefully remove the rear cover Front Cover Section Removal 9 The left and right hand cover sections must be removed before the front cover section can be removed 10 The front cover sectio...

Page 32: ...ers removed in step 11 Left Hand Cover Section Replacement 17 Set the left hand cover section in its mounting position and carefully snap its four tabs into the front cover section 18 Fasten the left hand cover section with the screws removed in step 2 Right Hand Cover Section Replacement 19 Set the right hand cover section in its mounting position and carefully snap its four tabs into the front c...

Page 33: ...Circuit Assembly 4 Remove the four screws that fasten the upper printed circuit assembly to the display front panel 5 Set the replacement upper printed circuit assembly in its mounting position on the display front panel and fasten it with the four screws removed in step 4 6 Set the display front panel near its mounting position and reconnect the data cable and heart rate cable to the upper printe...

Page 34: ...d be removed with a proper IC removal tool see the illustrations below 4 The IC s may inserted into their socket by hand by carefully aligning the notch on the IC with the notch on the IC socket and carefully pressing the IC into its socket See the illustrations below for the alignment notches Care must be taken that the IC legs on a DIP28 are all aligned in the socket to prevent the legs from ben...

Page 35: ...sembly See Diagram 7 1 4 Remove the four screws that fasten the upper printed circuit assembly to the display front panel 5 Set the upper printed circuit assembly removed in step 4 in its mounting position on the replacement display front panel and fasten it with the four screws removed in step 4 6 Set the display front panel near its mounting position and reconnect the data cable and heart rate c...

Page 36: ...that fasten the lower printed circuit assembly to its mounting bracket Diagram 7 2 Lower Printed Circuit Assembly Mounting 4 Set the replacement lower printed circuit assembly in its mounting position and fasten it with the four screws removed instep 3 5 Connect the red lead from the battery to the BAtTERY terminal Connect the black lead from the battery to BATTERY terminal 6 Connect the two red w...

Page 37: ...and white wires from the generator to the 3 PHASE GEN IN terminals These wires may be connected in any order 8 Connect the data cable to its connector on the lower printed circuit assembly 9 Replace the left hand and right hand covers per Procedure 7 1 ...

Page 38: ...efer to diagram 7 3 feed the belt into the stairarm foot plate through the slot in the front edge of the stairarm foot plate Replace the clamp and fasten the belt in the clamp with the bolts removed in step 3 7 Place the other belt clamp on the other end of the belt and fasten the belt clamp on the belt with the bolts removed in step 4 Hook the return spring into the belt clamp 8 Refer to diagram ...

Page 39: ...primary sheave when rotated toward the rear of the climber The replacement pulley must be mounted so it rotates in the same manner See Diagram 7 4 Diagram 7 4 HTD Pulley 5 Remove the retaining clip from the HTD pulley Remove the thrust washer from the shaft Slide the HTD pulley off of the shaft Verify that there are three thrust washers one wave washer and another thrust washer remaining on the sh...

Page 40: ...ed pulley Then lift the stairarm and hook the return spring on its mounting peg Check the belt to ensure there are no twists in the belt If there are remove the return spring from its mounting peg and rotate the return spring to remove any twist Hook the return spring on its mounting peg 8 Replace the left hand and right hand cover sections per Procedure 7 1 ...

Page 41: ... 7 5 Diagram 7 5 Lower Flanged Pulley 5 Set the replacement flanged pulley at its mounting position and fasten it with the bolt removed in step 4 Torque the mounting bolt to 120 inch pounds 6 Wrap the stairarm belt over the HTD pulley behind and under the upper flanged pulley Wrap the belt under an around the lower flanged pulley Then lift the stairarm and hook the return spring on its mounting pe...

Page 42: ...e retaining clip from one of the HTD pulleys Remove the thrust washer from the shaft Slide the HTD pulley off of the shaft Remove the remaining three thrust washers wave washer and another thrust washer from the shaft 6 Remove the remaining HTD pulley as described in step 5 7 Remove tension from the primary belt with the secondary sheave tension adjusters See Diagram 7 7 8 Remove the four bolts an...

Page 43: ... shaft Fasten the HTD pulley with the retaining clip removed in step 5 13 Replace the remaining HTD pulley as described in steps 11 and 12 14 Tension both the primary and generator belts as described in Procedure 5 2 15 Wrap one of the stairarm belts over the HTD pulley behind and under the upper flanged pulley Wrap the belt under and around the lower front flanged pulley Then lift the stairarm an...

Page 44: ...and allow it to lay on the primary sheave s shaft This will allow clearance for the removal of the secondary sheave 4 Remove the secondary sheave from both the primary and generator belts 5 Place the primary belt and generator belt around the replacement secondary sheave Set the secondary sheave in it mounting position Tension both the primary belt and generator belt per Procedure 5 2 6 Bend both ...

Page 45: ...de a thrust washer onto one of the primary sheave shafts then a wave washer and then three more thrust washers 5 Slide one of the HTD pulleys onto the shaft Verify that it rotates as described in step 4 of Procedure 7 7 Slide another thrust washer onto the shaft Fasten the HTD pulley with the retaining clip removed in step 5 6 Replace the remaining HTD pulley as described in steps 11 and 12 7 Plac...

Page 46: ...lacement generator belt on the secondary sheave along with the primary belt 3 Set the secondary sheave in it mounting position Hand start both secondary sheave tension adjusters 4 Place the generator belt around the generator pulley 5 Tension both the primary belt and generator belt per Procedure 5 2 6 Replace the left hand right hand and rear covers per Procedure 7 1 ...

Page 47: ...bar Mounting 2 While supporting the vertical handlebar remove both handlebar clamp nuts Carefully lower the vertical handlebar and then rotate it and set it on the left and right handlebars as shown in Diagram 7 9 Diagram 7 9 Vertical Handlebar Removal Handlebar Clamp Nut Vertical Handlebar Bolt Vertical Handlebar Handle Handlebar Clamp HHHR Connectors Vertical Handlebar Cable Access Hole ...

Page 48: ...tating the vertical handlebar assembly into its mounting position feed the hand held heart rate cable into the access hole in the upright column 6 Hand start but do not tighten the two handlebar clamp bolts removed in step 2 Hand start but do not tighten the two vertical handlebar bolts removed in step 1 7 Verify that both the left and right hand handlebars are fully inserted in the handlebar clam...

Page 49: ... the handlebar clamp and lift the handlebar from its lower rear mount 5 Remove the handlebar boot from the handlebar and install it on the replacement handlebar 6 Set the replacement handlebar on its lower rear mount and slide the upper end of the handlebar into the handlebar clamp 7 Verify that both the left and right handlebar are fully inserted in the handlebar clamp and tighten both handlebar ...

Page 50: ...plate shafts and remove the foot plate 4 Remove the bolts that retain the belt clamp and remove the belt from the foot plate 5 Set the replacement foot plate in its mounting position and replace both the long and short foot plate shaft as shown in Diagram 7 11 6 Verify that the ends of the foot plate shafts are flush with the edge of the foot plates Apply blue loctite to the set screws removed in ...

Page 51: ...d pulley Then lift the stairarm and hook the return spring on its mounting peg Check the belt to ensure there are no twists in the belt If there are remove the return spring from its mounting peg and rotate the return spring to remove any twist Hook the return spring on its mounting peg 9 Replace the left hand and or right hand cover sections per Procedure 7 1 ...

Page 52: ...irarm 4 The upper and lower stairarms are the same part Therefore the upper stairarm will also have bumper mounting holes If the upper stairarm is being replaced orient the stairarm so that the bumper mounting holes are facing downward 5 Verify that the black plastic spacer is on the stairarm mounting shaft and slide the replacement stairarm onto the stairarm mounting shaft 6 Fasten the stairarm w...

Page 53: ...ed circuit assembly See Diagram 7 13 Diagram 7 13 Generator Mounting 4 Remove the four screws that retain the lower printed circuit assembly Remove the lower printed circuit assembly and set it on a static safe surface 5 Remove the four screws that fasten the lower printed circuit assembly mounting plate to the generator See Diagram 7 14 Diagram 7 14 Lower Printed Circuit Assembly Mounting Plate L...

Page 54: ...que the four generator mounting bolts to 40 inch pounds 11 Set the lower printed circuit assembly mounting plate at its mounting position on the generator and fasten it with the screws removed in step 5 12 Set the lower printed circuit assembly in its mounting position on its mounting plate and fasten it with the screws removed in step 4 13 Connect the red lead from the battery to the BAtTERY term...

Page 55: ...C776i Stairclimber Page 55 17 Replace the left hand cover per Procedure 7 1 18 Check the C776i per Section Four ...

Page 56: ...e battery from the climber 5 Set the replacement battery in its mounting position with the red dot oriented as shown in Diagram 7 16 6 Set the battery bracket in its mounting position taking care to avoid touching the battery terminals with the battery bracket Fasten the battery bracket to the frame with the screws removed in step 3 7 Connect the red wire removed in step 2 to the battery terminal ...

Page 57: ... that fasten the display housing to the display column See Diagram 7 18 Carefully remove the display housing from the display column while extracting the data cable and heart rate cable from the display column 7 Remove the two front cover bracket screws See Diagram 7 19 Remove the two lower column mounting bolts and remove the front cover bracket from the climber 8 While supporting the display col...

Page 58: ... housing and out of its access hole where the vertical handlebars will mount See Diagram 7 9 Feed the data cable into the display column and out of its access hole as shown in Diagram 7 17 Diagram 7 19 Display Column Mounting Mounting Screw Display Housing Display Column Grommet Top Cover Upper Column Mounting Bolt Cover Bracket Mounting Screw Front Cover Bracket Lower Column Mounting Bolt ...

Page 59: ...er rear mount and slide the upper end of the handlebar into the handlebar clamp 20 Set the right handlebar on its lower rear mount and slide the upper end of the handlebar into the handlebar clamp 21 Fasten the lower rear handlebar with the bolt removed in Procedure 7 14 step 3 22 Slide the handlebar boot down into position and replace the endcap with the bolt removed in Procedure 7 14 step 2 23 S...

Page 60: ...C776i Stairclimber Page 60 Wiring Diagram 8 1 C776i UPCA J1 J4 Keyboard HHHR PCA J6 J2 3 Phase Gen In Generator Magnet R W BK LPCA R R Load Battery R BK Bat Bat ...

Page 61: ...C776i Stairclimber Page 61 Block Diagram 8 2 C776i ...

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