Precor Commercial Adaptive Motion Trainer C100i Service Manual Download Page 1 | Manualshive

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C100i Adaptive Motion Trainer

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C100i Adaptive Motion Trainer

Warning:

This service manual is for use by Precor trained service 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), preventative maintenance procedures, inspection and adjustment procedures,
troubleshooting procedures, replacement procedures and electrical block and wiring diagrams.

Acrobat Reader Users:

To move directly to a procedure, click the appropriate procedure in the bookmark section to the
left of this page. You may “drag” the separator bar between this page and the bookmark section
to change the size of the page being viewed.

© 2006 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law

20039-154

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Summary of Contents for Commercial Adaptive Motion Trainer C100i

Page 1: ...s 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 Acrobat Reader Users To move directly to a procedure click the appropriate procedure in the bookmark section to the left of this ...

Page 2: ...ip the unit with the optional external power supply or have an assistant pedal on the unit while voltage measurements are being taken Because of the danger of working on the unit while it is in motion using the optional external power supply is strongly recommended When the unit is used stairarms are in motion the generator will operate and produce potentially hazardous voltages even when the batt...

Page 3: ... like a wheelbarrow Safety guidelines you should know and follow include Read the owner s manual and follow all operating instructions Operate the C100i on a solid level surface with the unit properly leveled The C100i is properly leveled when all five feet are in contact with the floor Visually check the C100i before beginning service or maintenance operations If it is not completely assembled or...

Page 4: ...pply and coaxial cable routed through the bottom of the unit to the top of the display console Cord management must be maintained General Information For the latest exploded view part number and part pricing information visit the Precor dealer website at www precor com connection Tools Required Multimeter Allen wrench set Anti static kit Screwdriver set 4 6 gear puller Precor part number 20030 108...

Page 5: ... the surface of the electronic console with a damp sponge or soft cloth Dry with a clean towel A 30 1 solution of Simple Green and water or Contec Athletix wipes are the only cleaning products that have been tested and approved for use on the C100i The use of an acid citric based cleaner is not authorized by Precor Weekly Maintenance Vacuum underneath the C100i following these steps 1 Unplug the o...

Page 6: ...cian When you are called to service a C100i perform these preventive maintenance activities Perform the software diagnostics Check LED and keypad function Record the odometer reading Check stride rate and stride length sensor function is the stride rate and stride length displayed when the unit is in operation Visually inspect the drive belts for cracks fraying or excessive wear When furnished ins...

Page 7: ...he standard access codes use all sequential key presses The allowable delay between key presses is short If too much time is taken between key presses the access procedure will be aborted and the display will return to the idle state with the Precor banner displayed If the access is aborted it will be necessary to start over from the beginning Refer to Diagram 3 1 Standard Access Codes Diagnostics...

Page 8: ...n the T key KEYBOARD TEST will scroll across the display 7 Press the OK key a representation of all of the keys on the console will be displayed Pressing a key on the console will cause the representation of that key to go off Press all of the keys on the console to ensure that all of the keys are functioning 8 Press and hold the CLEAR key then the T key HEART RATE will be displayed 9 Grasp both o...

Page 9: ...ge will be displayed 19 Press the CLEAR key then the T key STRIDE POSITION TEST will scroll across the display 20 Press the OK key the low high and actual stride positions will be displayed The low display shows the lowest position reading achieved during the test The high display shows the highest position reading achieved during the test The actual display changes with the current stride positio...

Page 10: ...TION DISPLAY will scroll across the display 4 Use the S T keys to move to the desired display shown in the list above 5 ODOMETER display Press the OK key 6 The horizontal distance will be displayed in miles or kilometers and the vertical distance will be displayed in steps Note The odometer data is stored in non volatile memory on the upper PCA If the upper PCA is replaced the odometer data will b...

Page 11: ...s display the installed version of lower PCA software 21 Press the OK key The software part number will be displayed as XXXXX XXX 22 Press the CLEAR key to exit the lower SW display 23 STRIDE DIAL SW display This display the installed version of lower PCA software 24 Press the OK key The software part number will be displayed as XXXXX XXX 25 Press the CLEAR key to exit the lower SW display 26 SER ...

Page 12: ... motor current reading when the error occurred 35 If you wish to clear the error log press and hold the QUICK START key The message HOLD TO CLEAR ERRORS will be displayed The error log will be cleared when the message NO ERRORS is displayed 36 Press the RESET key to exit the information display 37 Please note that the ERROR LOG may also be accessed at any time by pressing and holding the RESET key...

Page 13: ...hen SELECT LANGUAGE is displayed Press the OK key 6 Use the S T keys to toggle between the available languages 7 Press the BACK key to exit the select language display 8 SELECT UNITS display Press the OK key 9 Use the S T keys to toggle between U S and METRIC measurements 10 Press the BACK key to exit the set units display 11 SET MAX WORKOUT TIME display Press the OK key 12 Use the S T keys to sel...

Page 14: ...14 17 SET COOL DOWN TIME display Press the OK key 18 Use the S T keys to select the cool down time from 0 to 5 minutes 19 Press the BACK key to exit the set cool down time display 20 Press the RESET key to exit the club settings program ...

Page 15: ...available the information below must be forwarded to Precor customer support This information will be used to correct and create new software whenever it is appropriate When a problem occurs record the following information Model and serial number Software part numbers Procedures 3 3 11 to 3 3 25 User and program number running when the problem occurred A description of a What happened or failed t...

Page 16: ...iode on the lower PCA will go out when the power supply is discharged approximately 45 seconds 2 If the CSAFE Full port is in use temporarily disconnect the RJ 45 cable from the CSAFE Full port If the CSAFE Full port is not in use temporarily remove the plastic plug from the CSAFE Full port Console Rear View with Rear Cover Removed 3 Connect the computer interface cable to the CSAFE Full port 4 Se...

Page 17: ...A to completely discharge The light emitting diode on the lower PCA will go out when the power supply is discharged 7 Start pedaling the C100i after it has been allowed to power down the C100i will now be operating on the newly uploaded software 8 Verify software version per Procedure 3 3 9 Thoroughly check the C100i s function per Section Four ...

Page 18: ...with the floor and there is no side to side rocking 6 If the C100i makes unusual noises or the electronic display does not change appropriately troubleshoot per Section 6 7 Press the RESISTANCE S key until you reach Resistance Level 10 Operate the C100i for another 2 3 minutes 8 If the C100i resistance does not change or the operation of the C100i feels inconsistent compared with Resistance Level ...

Page 19: ... lower PCA 5 With an ohmmeter read between the wires removed in step 5 The reading should be approximately 10 Replace the two wires removed in step 5 6 Remove the three wires from the 3 PHASE GEN IN terminals of the lower PCA 7 With an ohmmeter read between the red white red black and white black wires Each reading should be approximately 25 Reconnect the wires removed in step 7 8 If any of the re...

Page 20: ...C100i Adaptive Motion Trainer Page 20 Diagram 5 1 Lower PCA LOAD 3 PHASE GEN IN BATTERY ...

Page 21: ... per Procedure 7 12 2 Place a belt gauge to the primary belt as shown in Diagram 5 2 Diagram 5 2 Primary Belt Tension Adjustment 3 The belt gauge should read approximately 70 lbs If the belt tension is significantly high or low the belt tension may be adjusted by loosening the idler pulley mounting bolt and carefully prying against the idler pulley to obtain the correct belt tension When belt the ...

Page 22: ... of the brake belt using the belt gauge shown in Diagram 5 2 Belt tension should be 110 lbs 10 lbs 5 If the belt tension is incorrect adjust the belt tension using the adjustment bolt shown in Diagram 5 3 Diagram 5 3 Brake Belt Idler Pulley Mounting Bolt Brake Belt Adjustment Bolt ...

Page 23: ...4 inch thick bar stock between the upper and lower portions primary pulley and the frame as shown Diagram 5 4 4 Use the two adjustment bolts shown in Diagram 5 4 to align the primary pulley square to frame and a 1 4 from the frame 5 Torque the four pillow block mounting bolts to 60 65 foot pounds 720 780 inch pounds 6 Test the alignment of the drive belt by pedaling the unit in both the forward an...

Page 24: ...ht side cover 3 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 Section 4 If the unit works properly replace the interconnect cable as described in Procedure 7 3 6 If you have performed all of the procedures above and have been unable t...

Page 25: ...e 2 If the C100i powers up and functions normally until a particular key s is pressed skip to step 10 3 If a stuck key message is immediately displayed when the C100i is powered up continue with the next step 4 This condition may be caused by either the keypad or upper PCA 5 Remove the four screws that attach the display s rear cover 6 Unsnap display housing front panel from the display housing Re...

Page 26: ...iagnostic program is not functioning skip to step 14 11 Test the keypad per Procedure 3 2 12 If all of the keys test good the problem may be user error or a key function that is normally disabled during a particular user program 13 If one or more keys do not function correctly either the keypad display housing or upper PCA could be defective Replace the display and repeat step 12 If the display ho...

Page 27: ... 4 6 If the generator was found to be good the problem will be in either the lower PCA upper PCA or the upper to lower PCA interconnect cable Warning Because this is a self powered unit it will either be necessary to either equip the unit with the optional external power supply or have an assistant pedal on the unit while voltage measurements are being taken Because of the danger of working on the...

Page 28: ...hoot the upper to lower PCA interconnect cables per Procedure 6 1 11 If the upper to lower interconnect cable is 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 TP14 7 5V TP24 DGND ...

Page 29: ...ken Because of the danger of working on the unit while it is in motion using the optional external power supply is strongly recommended 1 Perform the generator resistance test per Procedure 5 1 If any of the resistance measurements are significantly high or significantly low replace the generator 2 The following voltage reading must be taken while the unit is in motion Extreme care must be taken t...

Page 30: ... hand held reading chest strap normal no hand held or chest strap reading or constant or intermittent readings when neither hand held or chest strap are in use Diagram 6 3 Hand held chest strap heart rate PCA Normal hand held reading No chest strap reading 1 Access the diagnostic program Procedure 3 2 Advance to the heart rate display portion of the diagnostic program Verify that a chest strap sig...

Page 31: ...t rate reading within ten seconds If a hand held signal is still not being accepted skip to step 10 9 If a hand held signal was accepted in step 11 the hand held contact wiring is reversed The end of the wire harness that connects to the hand held contacts in the handlebar is segregated into two groups One group has blue shrink wrap around it and the other group has black shrink wrap around it The...

Page 32: ... ground and 5 Vdc pins of the connector just removed from the heart rate PCA for 5 Vdc If 5 Vdc is present replace the heart rate PCA If the 5 Vdc is not present measure 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 neith...

Page 33: ...rning and Caution statements listed in Section One Things You Should Know 2 Attach the anti static wrist strap to your arm then connect the ground wire of the wrist strap to the units frame 3 Remove the four screws that secure the display s rear cover 4 Attach the wrist strap to your arm then connect the ground wire of the wrist strap to the C100i frame 5 Disconnect the interconnect cable and hear...

Page 34: ...location on the display housing front panel and snap it into place refer to Diagram 6 1 11 Reconnect the keyboard cable D pad cable and matrix PCA cable to the upper PCA See Diagram 6 1 12 Starting from the bottom and working upward snap the display front panel onto the display housing 13 Reconnect the interconnect and heart rate cables to the upper PCA 14 Remove the ground wire of the wrist strap...

Page 35: ...CA from its mounting bracket 6 Position the replacement lower PCA at its mounting position and snap it into its mounting bracket Fasten it with the screw removed in step 4 7 Reconnect the lower PCA wires as follows The battery wires are polarized to prevent them from being connected incorrectly Connect the black wire to the battery terminal nearest to the edge of the lower PCA and the red wire to ...

Page 36: ...Trainer Page 36 8 Remove the ground wire of the wrist strap from the C100i frame then remove the wrist strap from your arm 9 Re install the right side cover then check the operation of the C100i as described in Section Four ...

Page 37: ... One Things You Should Know 1 Remove the four screws from the display rear cover and remove the display rear cover 2 Disconnect the interconnect cable from the upper PCA See Diagram 7 3 Diagram 7 3 Display Rear View 3 Remove the four nuts that fastens the display to the column Remove the display and set it aside See Diagram 7 3 4 Remove the right side cover 5 Carefully cut and remove the tie wraps...

Page 38: ...at the top of the column 9 Set the display at its mounting position and fasten it with the four nuts removed in step 3 10 Connect the interconnect cable to the upper PCA and to the lower PCA as shown in Diagram 7 3 11 Dress the interconnect cable along the frame as shown in Diagram 7 3 and secure it with four tie wraps 12 Replace the display rear cover and the right side cover 13 Check the operati...

Page 39: ...sen but do remove the bolt that fastens the idler pulley and remove tension from the primary belt See Diagram 7 4 Diagram 7 4 Primary Belt 4 Remove the hardware that fasten the upper and lower connecting rod halves together Separate the lower connecting rod half from the upper connecting rod half See Diagram 7 4 5 Remove and discard the primary belt 6 Set the replacement primary belt in its mounti...

Page 40: ...ing rod half into the lower connecting rod half and fasten them with the hardware removed in step 4 Torque the connecting rod bolts to 17 21 foot pounds 200 250 inch pounds 9 Raise and insert the left side handlebar on its mount and fasten it with the hardware removed in step 2 10 Replace the left side cover ...

Page 41: ...ble from the speed sensor PCA 4 Loosen but do not remove the two bottom brake assembly mounting bolts Remove the two upper brake assembly mounting bolts Carefully remove the brake assembly and place it on a flat solid work surface 5 Loosen the belt tension adjustment bolt Remove the idler pulley mounting bolt and the idler pulley See Diagram 7 5 6 Remove the hardware that fasten the two spacers in...

Page 42: ...e idler pulley with the belt on the left side of the idler pulley and fasten it with the hardware removed in step 5 11 Carefully set brake assembly its two lower mounting bolts left in the frame in step 4 and hand start the upper brake assembly mounting bolts Torque the four brake assembly mounting to 17 21 foot pounds 200 250 inch pounds 12 Reconnect the speed sensor cable to the speed sensor PCA...

Page 43: ...mbly to the floor Repeat this procedure with the remaining upper arm weldment See Diagram 7 7 Diagram 7 7 Stairarm Rear Link Assemblies 3 Loosen but do not remove the idler pulley mounting bolt See Diagram 7 4 4 Remove the retaining clip from the lower end of the of the lower connecting rod half See Diagram 7 4 5 Remove the hardware that fasten the upper connecting rod half to the lower connecting...

Page 44: ...necting rod halves onto the primary pulley and fasten it with the retaining clip removed in step 4 14 Slide the upper connecting rod half into the lower connecting rod half and fasten it with the hardware removed in step 5 15 Repeat steps 13 and 14 with the remaining connecting rod halves 16 Raise one of the upper arm weldments and attach it to the upper arm casting and fasten it with the bolt rem...

Page 45: ... belt idler pulley mounting bolt See Diagram 7 4 3 Remove the primary belt from the generators pulley 4 Disconnect the generator wires at the midpoint connection See Diagram 7 8 Diagram 7 8 Generator Mounting 5 Remove the four generator mounting bolts and remove the generator 6 Set the replacement generator in its mounting position and fasten it with the hardware removed in step 5 Torque the gener...

Page 46: ... two red wires from the generators eddy current magnet to the green and brown wires in the midpoint cable the order does not matter Connect the red white and black wires from the generator to the red white and black wires in the midpoint cable 9 Replace the front cover Replace the left and right side covers ...

Page 47: ...ry out of the bracket 4 Slide the replacement battery into the plastic battery bracket so that the positive terminal red dot is on the right side and the negative terminal is on the left side 5 Connect the red wire removed in step 2 to the positive terminal red dot of the battery and the black wire removed in step 2 to the negative terminal of the battery 6 Replace the left side cover 7 Test the C...

Page 48: ...m 7 25 2 Remove the two bolts that fasten the stairarm to the rear link assembly Lower the stairarm to the floor See Diagram 7 9 Diagram 7 9 Stairarm and Rear Link Assembly 3 Remove the retaining clip and large washer that fastens the front of the stairarm to the front arm assembly See Diagram 7 10 Diagram 7 10 Stairarm and Front Arm Assembly Rear Link Stairarm Assembly Retaining Clip Large Washer...

Page 49: ...g The right hand view of Diagram 7 11 shows that the inner race of the near bearing has stayed on the stairarm This arrangement is typically what happens when the stairarm is removed 8 Remove the spacer the inner race two large washers and a wave washer from the stairarm The clearance between the stairarm shaft and the inner race is very small It is very easy to jam the inner race on the stairarm ...

Page 50: ... part way out of the bearing Using a small blunt tool gently tap the race back into the bearing 12 Set the foot pedal in its mounting position and fasten it with the hardware removed in step 4 13 Lift the stairarm and fasten it to the rear link assembly with the hardware removed in step 1 Torque the rear links assembly hardware to 100 110 inch pounds ...

Page 51: ...on Trainer Page 51 Procedure 7 10 Replacing a Upper Arm Casting Note This procedure was for use on older AMT s that have a two piece upper See Procedure 7 14 for replacing a two piece upper arm with a one piece upper arm ...

Page 52: ...H brake assembly See Diagram 7 12 Diagram 7 12 H Brake Tie Rod Mounting 3 Disconnect the sensor cable from the H brake assembly Remove the cable from the cable clamp on the H brake assembly See Diagram 7 13 Diagram 7 13 H Brake Sensor Cable 4 While supporting the H brake assembly it is heavy and you may wish to have an assistant support it remove the four H brake mounting bolts and remove the H br...

Page 53: ...ake mounting bolts to 200 250 inch pounds 17 21 foot pounds 6 Reconnect the sensor cable disconnected in step 3 and route it through its cable clamp 7 Fasten the tie rods to the H brake assembly with the hardware removed in step 2 Torque the tie rod hardware to 100 110 inch pounds 8 9 foot pounds 8 Replace the lower rear cover the left and right lower rear side covers upper rear cover left side co...

Page 54: ... mounting See Diagram 7 16 Remove the lower rear cover Diagram 7 16 Lower Rear Cover 2 Remove two screws one each side from left and right lower rear side covers See Diagram 7 17 Depress the tab at the rear of the covers and remove the left and right rear side covers Diagram 7 17 Lower Rear Side Covers Lower Rear Cover Left Lower Rear Side Cover Right Lower Rear Side Cover Tab Tab ...

Page 55: ...iagram 7 18 Upper Rear Cover 4 Remove two screws from the bottom edge of both side covers and remove both covers See Diagram 7 19 Diagram 7 19 Side Covers 5 Remove two screws from the lower portion of the front cover Grasp the lower portion of the front cover and remove the front cover See Diagram 7 20 Diagram 7 20 Front Cover Upper Rear Cover Side Cover Front Cover ...

Page 56: ...ce the left side cover using the procedure described in step 7 Diagram 7 21 Side Covers 9 Set the right rear side cover in its mounting position and engage the tab at the front of the cover in the clip in the lower cover Set the left rear side cover in its mounting position and engage the tab at the front of the cover in the clip in the lower cover Engage the tab and clip at the rear of the left a...

Page 57: ...0 Set the upper rear cover in its mounting position First slide the upper portion of the cover into place See Diagram 7 23 Press downward on the rear portion of the cover and snap it into place Diagram 7 23 Upper Rear Cover Upper Rear Cover ...

Page 58: ...agram 7 25 Diagram 7 25 Releasing the Lower Cover 3 Place a 9 16 end wrench on each of the hex head bolts that fasten the upper arm to the rear link These bolts thread into a free floating shaft remove one of the two bolts 4 Visually inspect the shaft where the bolt was removed in step 3 If a 1 4 hex slot is visible hold the shaft with a 1 4 allen wrench and remove the remaining bolt skip step 5 I...

Page 59: ...k mounting hardware apply blue loctite to the bolts and allow sufficient time for the loctite to cure New replacement hardware does not need to have loctite applied because it utilizes a loctite patch 10 Set the replacement rear link in its mounting position on the stairarm Use a quarter inch allen wrench to hold the free floating shaft thread one of the mounting bolts into the other side of the f...

Page 60: ... hex head bolts that fasten the upper arm to the rear link These bolts thread into a free floating shaft remove one of the two bolts 3 Visually inspect the shaft where the bolt was removed in step 2 There is a 1 4 hex slot in the shaft hold the shaft with a 1 4 allen wrench and remove the remaining bolt 4 Separate the upper arm from the rear link Diagram 7 29 Upper Connecting Rod Removal 5 Remove ...

Page 61: ...iagram 7 30 Bearing Removal 8 Slide inner bearing race 1 onto the upper arm mounting shaft 9 Ensure that the white plastic washer is on the upper arm see Diagram 7 31 slide the replacement upper arm onto inner bearing race 1 and into the upper connecting rod 10 Slide the black plastic spacer and inner bearing race 2 into the upper arm If necessary carefully tap it into place with a rubber mallet S...

Page 62: ...loctite to the bolts New replacement hardware does not need to have loctite applied because it utilizes a loctite patch 14 Set the replacement rear link in its mounting position on the upper arm Use a quarter inch allen wrench to hold the free floating shaft or the bolt and jam nut as described in step 4 thread one of the mounting bolts into the other side of the free floating shaft and torque it ...

Page 63: ...ner races of the bearings are not attached to the bearings and may come loose when the stairarm is removed See Diagram 7 11 4 Remove the upper arm per Procedure 7 14 steps 1 to 9 5 Slide the inner bearing race and black plastic spacer off of the upper arm mounting shaft and retain for later use See Diagram 7 30 6 Slide the front arm off of the upper arm mounting shaft 7 Clean the upper arm mountin...

Page 64: ...e shaft and against the large washers Slide the spacer onto the stairarm shaft The arrangement should be as shown in Diagram 7 36 above 13 Carefully slide the stairarm onto the inner race on the front arm assembly 14 Slide the remaining inner race that is in the arm into the far bearing and secure with the snap ring 15 Lift the stairarm and fasten it to the rear link assembly with the hardware rem...

Page 65: ...C100i Adaptive Motion Trainer Page 65 Wiring Diagram 8 1 C100i Self Powered ...

Page 66: ... J2 6 J 1 2 3 J 1 2 6 Microprocessor System Micrprocessor System Mid Point Connector J16 Load Generator BK W R BAT BAT R BK Heart Rate PCA J4 J1 1 J1 2 J1 3 J1 4 R R BK BK R i g h t T o p G r i p R i g h t B o t t o m G r i p L e f t T o p G r i p L e f t B o t t o m G r i p R R Load 3 Phase Gen In J13 J15 Metrics PCA D Pad PCA Stride Length J1 Keypad J11 Stride Length J2 J3 J14 J13 Flash Memory U...

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