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Precor C844 User Manual Download Page 44

C844 Upright Cycle

Page 44

Procedure 7.10 - Replacing the Gear Box

WARNING

Always turn off the C844 with the ON/OFF switch and unplug the power cord from the wall outlet 
before you service the cycle.

1.

Remove the upright covers from the pedestal weldment (see Diagram 7-6).

2.

Remove the crank arms as described in Procedure 7.9.

3.

Disconnect the lower ribbon cable from the upper ribbon cable. 

4.

Remove the upper frame assembly.

5.

Remove the bolts that secure the gear box to the pedestal weldment.

6.

Pull the gear box out of the pedestal weldment. Set aside the square key.

7.

Remove the rubber disk from the coupler. Remove the set screw that secures the coupler to 
the gear box.

Diagram 7-6  Replacing the Gear Box.

Summary of Contents for C844

Page 1: ...his 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 drag t...

Page 2: ...y and high voltage components When you perform maintenance procedures with the covers removed remove jewelry especially from ears and neck tie up long hair remove neck ties and do not wear loose clothing Exercise caution when touching any wire or electrical component during C844 operation The flywheel is very heavy Be prepared for the weight of the flywheel when it comes off of the flywheel shaft ...

Page 3: ...ver Do not set anything on the handlebars display enclosure or cover Never place liquids on any part of the C844 To prevent electrical shock keep all electrical components such as the power cord and circuit breaker away from water and other liquids Do not use accessory attachments that are not recommended by the manufacturer such attachments might cause injuries General Information For the latest ...

Page 4: ...ent that may be required when you service a Precor C844 Upright Cycle Tools Phillip and flat head screwdrivers Standard and metric allen wrench set Open end wrench set Socket wrench set Chip puller Rubber mallet Snap ring pliers Torque wrench Equipment Anti static kit Digital multimeter Supplies Cable ties ...

Page 5: ...lines sweep across the display 4 Watch the electronic display as the LED test progresses This test is programmed to display the following LED illumination sequence a Every LED on the left display window illuminates simultaneously b Horizontal vertical and diagonal lines of illuminated LED s sweep across the left display window c The right display windows illuminate then decrement from 8 8 8 8 to 0...

Page 6: ...TER then release 8 HArt is displayed in the right display window Put on the heart rate monitor 9 While using the Heart Rate Transmitter verify that the HEART RATE indicator blinks in time with your heart beat and the heart rate information displayed is correct THEN OTHERWISE Diagnostic software HArt mode checks Refer to the Smart Rate System correctly continue with the next step Service and Mainte...

Page 7: ... the column of light should be replaced by a single dot 11 Press each key listed BLANK ENTER BLANK STOP WORK LEVEL UP WORK LEVEL DOWN 12 If the appropriate sections of the left display window illuminated when the corresponding keys were pressed THEN OTHERWISE The keypad test passed successfully Replace the upper PCA as described continue with the next step in Procedure 7 1 13 Press ENTER and WORK ...

Page 8: ...sly and hold them until the message CYCLE ODOMETER scrolls across the left display window Note The right display window displays total miles or kilometers on the cycle see Diagram 2 2 The top display window shows the most significant bits of the number the lower display window shows the least significant bits of the number The number displayed is 102 187 723 in miles or kilometers 3 Press ENTER tw...

Page 9: ... the banner Metric 3 If you wish to change the measurement standard THEN OTHERWISE Use the UP or DOWN keys to toggle Continue with the next step to an alternate measurement standard then continue with the next step 4 Press ENTER then release The line voltage currently selected is displayed on the left display window 5 If you wish to toggle to the alternate line voltage THEN OTHERWISE Use the UP or...

Page 10: ...Cycle Page 10 THEN OTHERWISE Use the UP or DOWN keys to select Continue with the next step the new maximum workout time then continue with the next step 8 Press ENTER then release to return to the C844 Cycle banner ...

Page 11: ...lowing information Model and serial number Note The model serial number is located on the bottom of the lower crossbeam Software version number Odometer reading Note Determine the version number of the PROM mounted on the upper PCA as described in Procedure 2 1 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 u...

Page 12: ...arely damp sponge or soft cloth Dry with a clean towel CAUTION Keep water away from electronic components to prevent shock On Site Preventive Maintenance Service Technician Perform the following preventive maintenance tasks each time you are called to service a C844 Check the LED s mounted on the upper PCA and the function keys displayed on the elec tronic console by performing Procedure 2 1 Measu...

Page 13: ...al rubbing hitting grinding or squeaking noises 6 Press the WORK LEVEL UP key until you reach Work Level 5 Operate the cycle for another 2 3 minutes 7 If the resistance of the cycle does not change or the operation of the cycle feels inconsistent compared with Work Level 1 THEN OTHERWISE Refer to procedures 6 5 and 6 6 Continue with the next step 8 Press the WORK LEVEL UP key until you reach Work ...

Page 14: ...djustment slots the assembly must stay in place after it is moved 3 Place a 050 feeler gauge between the flywheel and each of the magnet coils that make up the magnet assembly 4 Choose one If the feeler gauge does not fit snugly THEN OTHERWISE Continue with the next step Skip to Step 6 5 Slide the magnet assembly along its adjustment slots until the feeler gauge fits snugly between the flywheel an...

Page 15: ...C844 Upright Cycle Page 15 Diagram 5 1 Adjusting the gap between the flywheel and magnet assembly ...

Page 16: ...t Measure the resistance between the two terminals Note The resistance of the magnets will be higher than optimum 90 110 ohms when they are warm Take resistance measurements when the magnets are at room temperature 4 If the resistance measures significantly less than 90 ohms or significantly more than 110 ohms THEN OTHERWISE Replace the magnet as described Connect the wires to the magnet in Proced...

Page 17: ...C844 Upright Cycle Page 17 Diagram 5 2 C844 Magnet Wiring ...

Page 18: ...wing steps Re check the gap between the couplers Rotate the couplers and check the gap until you you have checked the gap between the couplers at four different spots Skip to Step 8 4 Remove the set screw that secures the upper coupler to the gear box see Diagram 5 3 If necessary remove the old loc tite from the set screw 5 Adjust the position of the coupler on the gear box shaft until the feeler ...

Page 19: ...C844 Upright Cycle Page 19 Diagram 5 3 The Upper and Lower Couplers ...

Page 20: ...ower ribbon cable 6 Check the operation of the cycle as described in Section Four 7 If the cycle operated correctly when the spare ribbon cable was installed THEN OTHERWISE The original upper ribbon cable is bad The original upper ribbon cable is not install a new cable as described in defective continue with the next step Procedure 7 7 8 Disconnect the spare ribbon cable from the upper PCA and th...

Page 21: ...the spare ribbon cable from the lower PCA and the upper ribbon cable 17 Connect the original lower ribbon cable to the upper PCA 18 Install the pan to the base of the cycle Return the cycle to its upright position 19 Connect the upper ribbon cable to the lower ribbon cable 20 Remove the ground lead of the wrist strap from the C844 frame then remove the wrist strap from your arm 21 Install the upri...

Page 22: ...he upper display assembly to the upper handrail Carefully pull some excess interconnect cable out from the targa upright Rotate the display housing so that the rear of the upper PCA is facing upward and set the display housing on the upper handrail 3 Attach the wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill frame Set the voltmeter to a range that will conv...

Page 23: ...e keys do not function replace the upper PCA 8 If the voltage readings in Table 6 1 are incorrect disconnect the keypad cable from the key pad connector and repeat the voltage measuremnts in 6 1 If the voltage readings are now correct replace the display housing keypad If the voltage readings are still incorrect replace the upper PCA 9 If the voltage readings in Table 6 1 are correct and one or mo...

Page 24: ...fuse from the AC input module Using an ohmmeter check the fuse for continuity If the fuse does not read 1Ω or less replace the fuse Plug the AC line cord into the AC wall outlet and test the operation of the C844 4 Set the C844 on off switch in the on position Using an AC voltmeter check between the blue and brown wires on the load side of the on off switch terminals 1 4 If the AC voltage is incor...

Page 25: ... lower and upper PCA s Check the ribbon cable for cut or frayed wires If necessary replace the ribbon cable 11 If the voltage in step 8 measured 6 VDC 25 VDC and the upper display is not illuminated be sure that the U3 prom is correctly installed and firmly seated in its socket on the upper PCA If the prom is correctly installed replace the UPCA 12 If you have performed all of the previous tests a...

Page 26: ...AC input module Using an ohmmeter check the fuse for continuity If the fuse does not read 1Ω or less replace the fuse Plug the AC line cord into the AC wall outlet and test the operation of the C844 4 Set the C844 on off switch in the on position Using an AC voltmeter check between the blue and brown wires on the load side of the on off switch terminals 1 4 If the AC voltage is incorrect or missin...

Page 27: ...for cut or frayed wires If necessary replace the ribbon cable 11 If the voltage in step 8 measured 6 VDC 25 VDC and the upper display is not illuminated be sure that the U3 prom is correctly installed and firmly seated in it s socket on the upper PCA If the prom is correctly installed replace the UPCA 12 If you have performed all of the previous tests and have not been able to locate the trouble c...

Page 28: ...ge is correct with P6 disconnected replace reed switch 3 Using a DC voltmeter measure the voltage between pins 1 2 of P6 on the lower PCA Carefully rotate the flywheel When the magnet mounted in the flywheel passes the reed switch mounted on the frame the voltage should toggle between approximately 6 VDC to approximately 0 VDC After the magnet passes the reed switch the voltage should toggle back ...

Page 29: ...n Use wiring diagram 5 2 on page 5 5 to verify that the magnets are correctly wired If the wiring of one or more of the magnets is reversed the resistance will not be correct 6 Remove the P3 plug from the lower PCA and measure the voltage as in step 3 Perform the measurement on pins 1 2 of the P3 connector on the lower PCA The voltage should measure approximately 87 Vdc If the the voltage is missi...

Page 30: ...e the upper display module assembly to the upper frame member CAUTION When you perform the next step tape the ribbon cable to the C844 Transport to prevent it from falling into the upper frame member 2 Attach the wrist strap to your arm then connect the ground lead of the wrist strap to the C844 frame 3 Disconnect the ribbon cable from the upper PCA see Diagram 7 1 4 Remove the screws that secure ...

Page 31: ... Install the screws that secure the upper PCA to the display enclosure 9 Line up the blank place on the end of the keypad ribbon cable with the blank pin position on the keypad connector Place a full twist in the end of the keypad ribbon cable then carefully connect it to the upper PCA 10 Connect the ribbon cable to the upper PCA 11 Position the upper display module on the upper frame member Insta...

Page 32: ...e the screws that secure the display enclosure to the display plate 5 Carefully disconnect the ribbon cable keypad from the connector on the upper PCA 6 Remove the screws that secure the upper PCA to the display enclosure Replacing the PROM Keep the new PROM in its protective packaging until you are ready to insert it into the chip socket Caution Notice the orientation notch on the PROM see Diagra...

Page 33: ... display enclosure so that the display label is facing up 13 Remove the ground lead of the wrist strap from the C844 frame then remove the wrist strap from your arm 14 Check the operation of the C844 as described in Section Four 15 If the C844 operates correctly THEN OTHERWISE Continue with the next step Replace the upper PCA as described in Procedure 7 1 16 Attach the anti static wrist strap to y...

Page 34: ...trap from the C844 frame then remove the wrist strap from your arm 21 Position the upper display module on the upper frame member Install the screws that secure the display module to the upper frame member 22 Check the operation of the C844 as described in Section Four ...

Page 35: ...hown in Diagram 7 3 Always mark all wires before disconnecting to ensure quick accurate replacement 3 Disconnect the cables from the lower PCA 4 Remove the fasteners that secure the lower PCA to the cycle frame 5 Hold the replacement lower PCA against the cycle frame Install the fasteners that secure the lower PCA to the frame 6 Connect the cables you disconnected in Step 3 7 Remove the ground lea...

Page 36: ...C844 Upright Cycle Page 36 Diagram 7 3 C844 Wiring Diagram 120Vac Units ...

Page 37: ...ch out of the base plate 4 Position the new ON OFF switch at its mounting location 5 Connect the brown wire on the AC input module to terminal 2 of the ON OF switch 6 Connect the blue wire on the AC input module to terminal 3 of the ON OFF switch 7 Connect the brown wire on the lower PCA to terminal 1 of the the ON OFF switch 8 Connect the blue wire on the lower PCA to terminal 4 of the the ON OFF...

Page 38: ...e the screw that secures the green ground wire to the cycle frame 5 Depress the mounting tabs and push the AC input module out of the base plate 6 Position the new AC input module at its mounting position 7 Position the green ground wire at its mounting location Replace the screw that secures the green ground wire to the cycle frame 8 Connect the brown and blue wires disconnected in Step 3 to the ...

Page 39: ...ires that are connected to the input filter assembly 3 Remove the fasteners that secure the input filter assembly to the cycle frame 4 Position the new filter assembly at its mounting location 5 Install the connectors that secure the filter assembly to the cycle frame 6 Connect the wires removed in Step 2 to the new input filter assembly 7 Install the pan on the base of the cycle Return the cycle ...

Page 40: ... cable is defective as described in Procedure 6 1 WARNING Always turn off the C844 with the ON OFF switch and unplug the power cord from the wall outlet before you service the cycle 1 Remove the upright covers from the pedestal weldment 2 Disconnect the lower ribbon cable from the upper ribbon cable see Diagram 7 5 Diagram 7 5 C844 Ribbon Cables ...

Page 41: ... ribbon cable to the upper PCA per Steps 10 through 13 of Procedure 7 1 8 Choose one If you are installing a new lower ribbon cable on the cycle THEN OTHERWISE Continue with the next step Skip to Step 13 9 Place the C844 Cycle on its front end Remove the pan from the base of the cycle 10 Disconnect the lower ribbon cable from the lower PCA 11 Tape the upper end of the new lower ribbon cable to the...

Page 42: ...clockwise 2 Face the left side of the cycle Use an open end wrench to remove the left pedal from the crank arm Replacing the Pedals The pedals are marked with an R Right and an L Left When you replace the pedals make sure that the new pedals are mounted on the appropriate side of the cycle 3 Thread the right pedal connector counterclockwise onto the crank arm Tighten the pedal connector 4 Face the...

Page 43: ...ove the bolt that secures the crank arm to the crank axle 3 If you are removing a crank arm because it must be replaced with a new crank arm remove the pedal from the crank arm as described in Procedure 7 8 4 Place the crank arm on the crank axle Note The right and left crank arms must be pointing in opposite directions 5 Replace the bolt that secures the crank arm to the crank axle Torque to 45 5...

Page 44: ...t see Diagram 7 6 2 Remove the crank arms as described in Procedure 7 9 3 Disconnect the lower ribbon cable from the upper ribbon cable 4 Remove the upper frame assembly 5 Remove the bolts that secure the gear box to the pedestal weldment 6 Pull the gear box out of the pedestal weldment Set aside the square key 7 Remove the rubber disk from the coupler Remove the set screw that secures the coupler...

Page 45: ...r box the couplers must line up 10 Install the bolts that secure the gear box to the pedestal weldment 11 Inspect and adjust the gap between the upper and lower couplers as described in Procedure 5 3 12 Replace the upper frame assembly 13 Connect the upper ribbon cable to the lower ribbon cable 14 Replace the crank arms as described in Procedure 7 9 15 Install the upright covers on the pedestal we...

Page 46: ...wheel Note Look at the position of the magnet relative to the flywheel hub The magnet must be installed on the new flywheel in the same manner 5 Remove the screws that secure the magnet to the flywheel Mount the magnet on the new flywheel 6 Place the key on the inside of the flywheel hub 7 With the magnet facing the base of the cycle slide the flywheel onto the flywheel shaft 8 Using the snap ring...

Page 47: ... lower coupler Skip to Step 9 7 Remove the rubber disk from the coupler Remove the set screw that secures the coupler to the gear box Set aside the coupler If necessary remove the old loc tite on the set screw 8 Position the new coupler on the new gear box Install the set screw that secures the coupler to the gear box Push the rubber disk onto the coupler pegs 9 Remove the set screw that secures t...

Page 48: ...rs as described in Procedure 5 3 15 Replace the upper frame assembly 16 Connect the upper ribbon cable to the lower ribbon cable 17 Install the upright covers on the pedestal weldment 18 Check the operation of the cycle as described in Section Four If operation feels rough loosen the bolts that secure the pedestal weldment to the cycle frame see Diagram 7 8 Pedal the cycle a few times Tighten the ...

Page 49: ...e wall outlet before you service the cycle 1 Place the C844 Cycle on its front end Remove the pan from the base of the cycle 2 Disconnect the magnet harness from the lower PCA see Diagram 7 9 3 Remove the screws that secure the magnet assembly to the frame see Diagram 7 10 4 Remove the magnet assembly from the cycle Diagram 7 9 The C844 Magnet Cable Assembly ...

Page 50: ...net assembly 6 Lightly tighten the two screws that secure the magnet assembly to the cycle frame 7 Inspect the gap between the flywheel and one of the magnet assemblies as described in Procedure 5 1 8 Tighten the two screws that mount the magnet assembly to the cycle frame 9 Connect the magnet harness to the lower PCA 10 Install the pan to the base of the cycle Return the cycle to its upright posi...

Page 51: ...e cycle 2 Disconnect the transformer cable from the lower PCA 3 Remove the screws that secure the transformer to the cycle frame 4 Remove the transformer from the cycle 5 Position the new transformer on the cycle 6 Install the screws that mount the transformer to the cycle frame 7 Connect the transformer cable to the lower PCA 8 Install the pan to the base of the cycle Return the cycle to its upri...

Page 52: ...ed in Procedure 7 11 3 Disconnect the reed switch cable from the lower PCA 4 Remove the screws that secure the reed switch to the cycle frame 5 Position the new reed switch against the cycle frame 6 Install the screws that secure the reed switch to the cycle frame 7 Connect the reed switch cable to the lower PCA 8 Install the flywheel as described in Procedure 7 11 9 Install the pan to the base of...

Page 53: ... the detent pin and spring from the top of the seat column 4 Push the detent pin through the spring then position the detent pin inside of the seat column Push the smaller end of the detent pin through the mounting holes in the seat column and seat pin housing 5 Hold the larger end of the detent pin and spring assembly against the inside of the seat column Note Keep the detent pin and spring assem...

Page 54: ...he handlebar assemblies to the handlebar clamps 2 Remove the handlebar assemblies from the handlebar clamp 3 Position a new handlebar assembly in a handlebar clamp Make sure that the handlebar assembly reaches the middle of the clamp 4 Replace the bolts that secure the handlebar assembly to the handlebar clamp 5 Repeat Step 3 and 4 for the remaining handlebar assembly Make sure that the handlebar ...

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