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5.33 Ellipitical Fitness Crosstrainer

Page 38

Procedure 7.3 - Replacing a Lower PCA

Warning:

Care must be taken when work is being performed in the area of the stairarms. Pinch

points exist between the stairarm and ramp and between the stairarm and crankarm,
when the rear covers are removed.

Procedure

Set the on/off switch in the “off” position.

WARNING

Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.

Remove the left and right rear cover sections.

Attach the wrist strap to your arm, then connect the ground lead of the wrist strap to the EFX
frame.

For serial code AAAB, skip to step 11. For serial codes CR and ST, continue with step 5.

Disconnect the magnet, speed sensor and A.C. cables from the lower PCA. See Diagram
7.4. Remove two screws that secure the lower PCA mounting bracket to the frame.

Diagram 7.4 - Lower PCA (serial codes CR and ST, front and rear views)

Interconnect

Speed

Sensor

Cable

A.C.

Cable

Magnet

Cable

Mounting Bracket

Screws

cable

Содержание EFX 5.33

Страница 1: ...and maintain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures tro...

Страница 2: ...e a EFX 5 33 component Removing the covers exposes high voltage components and potentially dangerous machinery Exercise extreme caution when you perform maintenance procedures with the hood removed Du...

Страница 3: ...splay enclosure or cover Never place liquids on any part of the EFX 5 33 other than a water bottle in the water bottle holder during normal operation To prevent electrical shock keep all electrical co...

Страница 4: ...UIPMENT phillips and flat head screwdrivers anti static wrist strap 20024 101 digital multimeter standard and metric allen wrench sets open end wrench set Supplies blue loctite drive ratchet and ratch...

Страница 5: ...1 Plug the power cord into the wall outlet then turn on the EFX 5 33 with the on off switch Note For the purpose of entering the key sequences to access the various diagnostic programs the keypad key...

Страница 6: ...layed When a key is pressed the representation of the key will be turned off Check all of the keys on the keyboard in this manner THEN OTHERWISE The keyboard test passed successfully Troubleshoot the...

Страница 7: ...e display and the corresponding power bits duty cycle will be displayed on the right side of the display Initially the power bits level will be zero pressing the keys will change the number of power b...

Страница 8: ...urs of use Fractional parts of an hour are stored internally the display will be truncated to the nearest full hour 8 Press the ENTER key to proceed to the software version display 9 The display name...

Страница 9: ...l 2 seconds will clear all existing entries from the error log The display will confirm that the error log has been cleared by displaying OK The display will revert to the first log entry and show it...

Страница 10: ...layed press keys RESET 5 6 7 1 sequentially 3 The display name SELECT UNITS will be displayed for 2 seconds 4 One of two measurement standards will be displayed U S Standard or Metric 5 If U S Standar...

Страница 11: ...e following information Model and serial number Software version numbers for upper and lower PCA s Note Look at the PROM mounted on the upper PCA A label on the PROM indicates the software version num...

Страница 12: ...Each Day Wipe down the stairarms ramps wheels and frame with a damp cloth Every Week Wipe the surface of the electronic console with a slightly damp sponge or soft cloth Dry with a clean towel CAUTIO...

Страница 13: ...ual noises or the electronic display does not change appropriately troubleshoot per section 6 6 Press the RESISTANCE key until you reach Resistance Level 10 Operate the EFX for another 2 3 minutes 7 I...

Страница 14: ...ning and Caution statements listed in Section One Things You Should Know 1 Remove the rear cover as described in Procedure 7 1 2 Set the ohmmeter to a range that will conveniently read up to 125 3 Dis...

Страница 15: ...d Reconnect the magnet wires then in Procedure 7 13 continue with the next step 5 Re install the rear cover as described in Procedure 7 1 then check the operation of the unit as described in Section F...

Страница 16: ...he right and left step up belt tension bolts have locking tabs If necessary use pliers to bend the locking tabs out of the way so that the bolts can be turned 7 If the step up pulley belt is out of al...

Страница 17: ...th of the belt and beside the belt gauge Slide one of the o rings up against the shoulder of the belt gauge Press downward on the belt gauge causing the belt to deflect Read the deflection on the belt...

Страница 18: ...quarter turn increments until the belt tensioning gauge reads 14 16 pounds 1 4 deflection 17 Verify that the belt alignment is still correct by performing the procedure in step 4 18 When both the step...

Страница 19: ...adjustment slot See Diagram 5 3 to the left of the pulley Using the screwdriver as a lever press the pulley to the right While maintaining constant pressure on pulley check the belt tension with your...

Страница 20: ...ate one of the crankarms to the twelve o clock position and measure the distance from the crankarm to the frame weldment See Diagram 5 5 Rotate the opposite crankarm to the twelve o clock position and...

Страница 21: ...h 7 Torque the three loose pillow block mounting nuts to 80 inch pounds Input Drive Axle to Step Up Pulley Axle Alignment 8 Mark the current position of the step up pulley on both side of the drive we...

Страница 22: ...ddy current magnet relative to the eddy current disk The eddy current disk should be centered in the slot in the eddy current magnet See Diagram 5 8 Diagram 5 8 Eddy Current Magnet 16 If the eddy curr...

Страница 23: ...are troubleshooting an error 30 31 or 32 continue with step 3 otherwise see Procedure 6 5 3 Pry the end cap out of the front of the frame base tube See Diagram 6 1 4 Carefully withdraw both cables an...

Страница 24: ...r and continue with step 7 8 Remove the upper display housing per Procedure 7 2 steps 1 to 4 Disconnect the upper interconnect cable from the mid point connector Substitute a known good interconnect c...

Страница 25: ...EFX powers up and functions normally until a particular key s is pressed skip to step 11 3 If a error 5 key depressed message is immediately displayed when the EFX is powered up continue with the next...

Страница 26: ...s the diagnostics program per procedure 2 1 If the key s necessary to access the diagnostic program is not functioning skip to step 14 12 Test the keypad per Procedure 2 1 step 6 13 If all of the keys...

Страница 27: ...gs You Should Know Procedure 1 Remove the right rear cover section per Procedure 7 1 Set the on off switch in the on position Operate the unit If the system timer has not started and a stride rate is...

Страница 28: ...ensor per Procedure 7 12 Skip to step 8 5 With the an ohmmeter connected to terminals 1 and 5 of J8 on the lower PCA rock the step up disk forward and backward so that the magnet is passing in front o...

Страница 29: ...f the voltage is missing or significantly low skip to step 4 If the voltage is correct continue with step 3 3 Set the on off switch in the off position Check the magnet wiring per Diagram 8 1 If any o...

Страница 30: ...ires at the lower PCA The measurement should be approximately 90 to 110 If the measurement is significantly low check the connections at both magnets and the lower PCA 11 With an ohmmeter measure betw...

Страница 31: ...in the on position Check between the power terminals of the line cord with an ohmmeter The ohmmeter reading should read infinity serial codes CR and ST or 1 to 1 5 megohm serial code AAAB 7 If the rea...

Страница 32: ...terminals 1 and 8 of the data cable connector on the lower PCA with a DC voltmeter See Diagram 6 5 or Diagram 6 6 The reading should be approximately 8 3 Vdc if the measurement is good replace the up...

Страница 33: ...5 33 Elliptical Fitness Crosstrainer Page 33 Diagram 6 6 Lower PCA serial code AAAB Data Cable Speed Connector Sensor AC Input Wiring Magnet Cable...

Страница 34: ...front top left and right sections If the front cover section is being removed the frame cover must also be removed See Diagram 7 1 3 If you are removing either the right or left cover section it is on...

Страница 35: ...fit the front cover against the frame cover Slide the front and frame covers into place as a unit Replace and tighten the four phillips screws that fasten the frame cover to the frame Replace and tigh...

Страница 36: ...ents listed in Section One Things You Should Know 2 Attach the anti static wrist strap to your arm then connect the ground lead of the wrist strap to the units frame 3 Remove the four screws that secu...

Страница 37: ...8 Reconnect the keyboard cable to the upper PCA 9 Reconnect the upper interconnect cable and heart rate cable to the upper PCA 10 Remove the ground lead of the wrist strap from the EFX frame then remo...

Страница 38: ...aution statements listed in Section One Things You Should Know 2 Remove the left and right rear cover sections 3 Attach the wrist strap to your arm then connect the ground lead of the wrist strap to t...

Страница 39: ...sition Fasten the mounting bracket to the frame with the screws removed in step 5 10 Connect the cables disconnected in Step 4 See Diagram 7 4 Skip step 15 Diagram 7 5 Lower PCA serial code AAAB 11 Re...

Страница 40: ...0 15 Remove the ground lead of the wrist strap from the EFX frame then remove the wrist strap from your arm 16 Re install the left and right rear cover sections per Procedure 7 1 Check the operation o...

Страница 41: ...both cables and mid point connector Diagram 7 6 Interconnect Cables and Mid Point Connector 4 If you are replacing the upper interconnect cable skip to step 9 If you are replacing the lower interconn...

Страница 42: ...g aside Disconnect the interconnect cable from the upper PCA See Diagram 7 3 Remove the four screws that fasten the display housing backplate to the main column Remove the display housing backplate 10...

Страница 43: ...7 7 Power Entry Module 3 Remove the blue wire from terminal D the brown wire from terminal A and the green wire from the ground terminal of the power entry module 4 Remove the two screws that fasten t...

Страница 44: ...eplace the wires removed in step 3 Connect the blue wire to terminal D the brown wire to terminal A and the green wire to the ground terminal of the power entry module 9 Replace the left and right cov...

Страница 45: ...ne Things You Should Know 2 Remove the left and or right cover section as described in Procedure 7 1 3 Remove the left and or right stairarm assembly as described in Procedure 7 17 Note Notice the pos...

Страница 46: ...ue the bolt to 300 in lbs 8 Replace the stairarm assembly as described in Procedure 7 17 9 If you are replacing both crankarm assemblies repeat steps 8 and 9 for the second crankarm assembly 10 Set th...

Страница 47: ...input pulley and step up pulley belts as described below a Loosen the input belt tensioner axle nut and turn the input belt tensioner adjustment bolt counterclockwise until tension is removed from th...

Страница 48: ...code AAAB 10 Thread and hand tighten the pillow block mounting nuts onto the mounting studs or mounting bolts Torque the pillow block mounting nuts to 80 in lbs 11 Tighten the right and left hand ten...

Страница 49: ...ure 5 2 13 Replace the crankarm s per Procedure 7 6 14 Replace the eddy current magnet per Procedure 7 13 15 Check the input drive adjustment per procedure 5 3 16 Replace the stairarms per Procedure 7...

Страница 50: ...re continuing with this procedure review the Warning and Caution statements listed in Section One Things You Should Know 2 Remove the front top left and right cover sections as described in Procedure...

Страница 51: ...ep up and input belts onto the input drive assembly as you set the input drive assembly in it s mounting position in the EFX 9 Replace the magnet assembly per Procedure 7 13 10 Complete the installati...

Страница 52: ...described in Procedure 7 13 6 Remove tension from the drive belts and remove the pillow block bearings per Procedure 7 7 steps 6 to 8 7 Slide the step up and input belts off of the input drive assemb...

Страница 53: ...input belts onto the input drive assembly as you set the input drive assembly in its mounting position in the drive unit 13 Slide the pillow block bearings onto the input pulley shaft 14 Complete the...

Страница 54: ...Remove tension from the drive belts and remove the pillow block bearings per Procedure 7 7 steps 6 to 8 7 Remove the input drive assembly from the unit See Diagrams 7 10 and 7 11 8 Remove the four bol...

Страница 55: ...Diagram 7 13 Step Up Pulley Belt 13 Slide the pillow block bearings onto the input pulley shaft 14 Complete the installation alignment and tensioning per Procedure 7 7 steps 9 to 17 Step Up Pulley St...

Страница 56: ...he drive belts 7 Slide the step up and input belts off of their pulleys 8 Remove the left and right tension bolts locking tabs and brackets 9 Carefully lay the EFX on it s side Remove the four bolts t...

Страница 57: ...ecures the speed sensor assembly to the drive unit remove the speed sensor See Diagram 7 14 5 For serial code AAAB unsnap the speed sensor from the speed sensor clip and remove the speed sensor See Di...

Страница 58: ...ness Crosstrainer Page 58 8 Reconnect the speed sensor cable to the lower PCA 9 Re install the left and right cover sections as described in Procedure 7 1 then check the operation of the EFX as descri...

Страница 59: ...in Section One Things You Should Know 2 Remove the left and right cover sections as described in Procedure 7 1 3 For serial code AAAB skip to step 10 For serial codes CR and ST continue with step 4 4...

Страница 60: ...r 10 Disconnect the magnet cable from the lower PCA See Diagram 6 6 11 Remove the bolts that fasten the eddy current magnet to its frame mounting See Diagram 7 16 Diagram 7 16 Eddy Current Magnet seri...

Страница 61: ...aution statements listed in Section One Things You Should Know 2 Remove the left and or right cover sections as described in Procedure 7 1 3 Remove the mounting bolt and nut that fastens the stairarm...

Страница 62: ...pin and replace the retaining ring removed in step 5 7 Slide the stairarm onto the stairarm pivot block Install and hand tighten the stairarm pivot block mounting hardware Torque the stairarm pivot b...

Страница 63: ...rews from the wheel axle If when removing the second wheel axle screw the axle rotates and the screw does not unthread insert a 5 32 allen wrench into the end of the axle from which the screw has been...

Страница 64: ...edure 1 Set the on off switch in the off position then unplug the power cord from the wall outlet 2 Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm 3 Remove the staira...

Страница 65: ...and nut that fastens the stairarm pivot block to the stairarm See Diagram 7 17 7 Slide the stairarm off of the stairarm pivot block 8 Set the stairarm pedal at it s mounting position on the replaceme...

Страница 66: ...r Procedure 7 1 3 Remove three bolts washers and single nut that fasten the stairarm connector to the stairarm See Diagram 7 25 4 Rotate both stairarms to the rear so that they are resting on the floo...

Страница 67: ...amp bracket 13 Torque the four bolts between the ramp and rear ramp bracket to 12 ft lbs Torque the two bolts between the ramp and the front ramp support to 20 ft lbs 14 Replace the ramp end cap with...

Страница 68: ...e upper pivot 4 Set the replacement handlebar in it s mounting position and hand start the three bolts and washers removed in step 3 that fasten the handlebar to the upper pivot 5 Hand start the bolt...

Страница 69: ...th this procedure review the Warning and Caution statements listed in Section One Things You Should Know 2 Remove the left and right cover sections as described in Procedure 7 1 3 Remove the input bel...

Страница 70: ...ss the pulley to the right While maintaining constant pressure on pulley check the belt tension with your finger When the belt tension feels correct tighten and torque the input belt tension bolt to 2...

Страница 71: ...edure 1 Set the on off switch in the off position 2 Remove three bolts and washers that fasten the handlebar to the upper pivot 3 Rotate the handlebar forward so that it is resting on the floor 4 Remo...

Страница 72: ...handlebar back into position against the upper pivot and fasten the handlebar to the upper pivot with the bolts and washers removed in step 2 Torque the bolts to 156 in lbs 7 Set the on off switch in...

Страница 73: ...1 Procedure 1 Set the on off switch in the off position 2 Remove the bolt that fastens the handlebar to the secondary link 3 Remove the retaining ring that fastens the secondary link to the stairarm...

Страница 74: ...ness Crosstrainer Page 74 6 Fasten the secondary link to the handlebar with the bolt removed in step 2 Torque the bolt to 156 in lbs 7 Set the on off switch in the on position and thoroughly test the...

Страница 75: ...ers are removed 1 Procedure 1 Set the on off switch in the off position 2 Remove the retaining clip that fastens the secondary link to the stairarm connector 3 Remove three bolts washers and single nu...

Страница 76: ...e the two bottom bolts to 50 in lbs Torque the horizontal bolt to 11 ft lbs 5 Replace the retaining ring that fastens the secondary link to the stairarm connector 6 Set the on off switch in the on pos...

Страница 77: ...CA Remove the display housing front panel 5 Remove the four screws that fasten the display backplate to the upper main column Remove the display housing backplate 6 Pry the end cap out the front of th...

Страница 78: ...em to 240 in lbs 15 Replace the left and right frame tubes per Procedure 7 25 steps 5 7 16 Rotate the right hand handlebar with upper pivot into it s mounting position Thread the upper pivot into the...

Страница 79: ...upper end of the frame tube to the main column Remove the frame tube 5 Set the replacement frame tube at it s mounting position and hand start the bolts with washers at the upper end of the frame tube...

Страница 80: ...emove the front top left and right rear cover sections per Procedure 7 1 3 Remove three bolts washers and single nut that fasten the right stairarm connector to the right stairarm Remove three bolts w...

Страница 81: ...racket 13 Torque the four bolts between the ramp and rear ramp bracket to 12 ft lbs Torque the two bolts between the ramp and the front ramp support to 20 ft lbs 14 Replace the ramp end cap with the s...

Страница 82: ...right rear cover sections per Procedure 7 1 3 Remove three bolts washers and single nut that fasten the right stairarm connector to the right stairarm Remove three bolts washers and single nut that fa...

Страница 83: ...bracket 13 Torque the four bolts between the ramp and rear ramp bracket to 12 ft lbs Torque the two bolts between the ramp and the front ramp support to 20 ft lbs 14 Replace the ramp end cap with the...

Страница 84: ...he two screws that mount the power entry module to the rear cover support 5 Remove the four screws that fasten the rear cover support to the frame base Remove the rear cover support 6 Set the replacem...

Страница 85: ...ainer Page 85 9 Replace the top left and right cover sections per Procedure 7 1 10 Insert the A C line cord in the power entry module and the A C outlet 11 Set the on off switch in the on position and...

Страница 86: ...Power Entry Module Fuse serial codes CR and ST 3 Using a thin bladed screwdriver carefully pry the fuse module out of the power entry module 4 The fuse module contains two fuses carefully remove one...

Страница 87: ...lliptical Fitness Crosstrainer Page 87 Diagram 7 32 Power Entry Module Fuse serial code AAAB 8 Set the on off switch in the on position and test the EFX per Section Four Power Entry Module Fuse Module...

Страница 88: ...he front inside and rear of the handlebar to stairarm link Remove and discard the handlebar to stairarm link 4 Slide one of the spacers removed in step 3 into the front of the replacement handlebar to...

Страница 89: ...tical Fitness Crosstrainer Page 89 6 Torque the both the front and rear handlebar to stairarm link mounting bolts to 156 inch pounds 7 Set the on off switch in the on position and test the EFX per Sec...

Страница 90: ...ackage PLCC44 Each of these packages should 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 th...

Страница 91: ...5 33 Elliptical Fitness Crosstrainer Page 91 Wiring Diagram 8 1 5 33 120 Vac serial codes CR and ST Lower PCA Upper PCA P1 J2 Power Entry Module B C GND G Mid Point Connector J9 J10...

Страница 92: ...5 33 Ellipitical Fitness Crosstrainer Page 92 Block Diagram 8 2 5 33 120 Vac Serial codes CR and ST...

Страница 93: ...33 Elliptical Fitness Crosstrainer Page 93 Wiring Diagram 8 3 5 33 120 Vac Serial code AAAB Upper PCA Lower PCA P1 J2 J2 J3 BK J7 1 J7 2 J1 2 J1 1 J6 2 5 8 J6 1 4 7 J6 6 J6 3 J7 2 5 8 J7 1 4 7 J7 6 J7...

Страница 94: ...5 33 Ellipitical Fitness Crosstrainer Page 94 Block Diagram 8 4 Block Diagram Serial code AAAB ADFJ...

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