Precor C842i Service Manual
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Precor C842i Service Manual

Precor C842i Service Manual

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C842i, C846i Upright and Recumbent Cycle
C842i, C846i Bicycle
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.
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.
© 2004 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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Summary of Contents for Precor C842i

  • Page 1 C842i, C846i Bicycle 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.

  • Page 2: Section One - Things You Should Know

    Section One - Things You Should Know Right, Left, Front, and Back Conventions In this manual, right, left, front, and back are from the perspective of a user sitting on the C842i or C846i, facing the display enclosure. Warning and Caution Statements and General Safety Guidelines Warning statements indicate a particularly dangerous activity.

  • Page 3: General Information

    Do not use accessory attachments that are not recommended by the manufacturer, such attachments might cause injuries or damage to the unit. General Information For the latest exploded view diagram, part number and part pricing information, visit the Precor dealer website at “www.precor.com/connection”. Page 3...

  • Page 4: Required Tools And Equipment

    C842i, C846i Upright and Recumbent Cycle Required Tools and Equipment The following is a summary of the tools and equipment that may be required when you service a Precor C842i, or C846i Upright or Recumbent Cycle. Tools Phillip and flat-head screwdrivers...

  • Page 5: Section Two - Preventive Maintenance

    Regular Preventive Maintenance (Owner) Cleanliness of the cycle and its operating environment will keep maintenance problems and service calls to a minimum. Precor recommends that you perform the following preventive maintenance schedule. After Each Use •...

  • Page 6: Quarterly Maintenance

    Check the belt tension of both belts per Procedures 5.1 and 5.2. Replace both covers. On-Site Preventive Maintenance (Service Technician) When you are called to service a C842i, or C846i, perform these preventive maintenance activities: • Perform the software diagnostics. Check LED and keypad function. Record the odometer reading.

  • Page 7: Procedure 3.1 - Accessing The Diagnostic Software

    C842i, C846i Upright and Recumbent Cycle Procedure 3.1 - Accessing the Diagnostic Software The treadmill's diagnostic software consists of the following modes: • Display Test • Keyboard Test • Heart Rate Test • Machine Test Procedure Using the RESET key and the numeric keypad, press keys RESET,5,1,7,6,5,7,6,1, sequen- tially.
  • Page 8 C842i, C846i Upright and Recumbent Cycle Press the OK key, the upper most group of LED’s will illuminate on the display. Check the display to ensure that all LED segments are illuminated. Press the OK key four more times to display the remaining LED groups. Check each display group to ensure that all LED segments are illuminated.

  • Page 9: Procedure 3.2 - Information Display

    Error Log Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the PRECOR banner scrolling, press the keys RESET,6,5, sequentially. DIAGS-INFORMATION DISPLAY will scroll across the display. Use the keys to move to the desired display shown in the list above.
  • Page 10 C842i, C846i Upright and Recumbent Cycle 11. U-BOOT SW display. This display the installed version of upper boot software. The boot software is used to upload new software into the upper display PCA. 12. Press the OK key. The software part number will be displayed as XXXXX-XXX.

  • Page 11: Procedure 3.3 - Selecting Club Settings

    C842i, C846i Upright and Recumbent Cycle Procedure 3.3 - Selecting Club Settings Procedure This procedure allows you to change the following club settings: • Select Language • Select Units • Set Max Workout Time • Set Max Pause Time •...
  • Page 12 C842i, C846i Upright and Recumbent Cycle 17. SET COOL DOWN TIME display. Press the OK key. 18. Use the keys to select the cool down time. 19. Press the BACK key to exit the set cool down time display. 20. SET RESISTANCE RANGE display. Press the OK key.

  • Page 13: Procedure 3.4 - Documenting Software Problems

    If you isolated the problem to either the PROM, upper PCA, or lower PCA, include the information you recorded with the malfunctioning PROM or PCA when you ship it to Precor. When a problem occurs, record the following information: •...
  • Page 14 C842i, C846i Upright and Recumbent Cycle Section Four - Checking C842i, or C846i Operation This section provides you with a quick method of checking operation. Procedure On C846 version 1 units, set the on/off switch in the “on” position. Start pedaling.

  • Page 15: Procedure 5.1 - Primary Drive Belt Adjustment

    C842i, C846i Upright and Recumbent Cycle Procedure 5.1 - Primary Drive Belt Adjustment Remove the left, right and top covers. Place the belt tension gauge, as shown in Diagram 5.1, on the primary belt. Diagram 5.1 - Primary Belt Tensioning C842i, C846i Belt Gauge Primary...

  • Page 16: Procedure 5.2 - Secondary Drive Belt Adjustment

    Procedure 5.2 - Secondary Drive Belt Adjustment Remove both side covers and the top cover. Place the belt tension gauge, as shown in Dia- gram 5.2, on the secondary belt. Diagram 5.2 - Secondary Belt Tensioning C842i, C846i Belt Gauge...

  • Page 17: Procedure 5.3 - Recumbent Seat Adjustment

    C842i, C846i Upright and Recumbent Cycle Procedure 5.3 - Recumbent Seat Adjustment Perform this procedure if the front to rear movement of the seat is too tight or there is excessive side to side seat wobble. Loosen but do not remove the four mounting screws on the left and right seat adjustment plates.

  • Page 18: Procedure 6.1 - Troubleshooting The Interconnect Cables

    Remove the display housing per Procedure 7.13. Disconnect the upper interconnect cable from the upper PCA. Disconnect the upper interconnect cable from the junction block between the column and the main frame. .Diagram 6.1 - Interconnect Cables, C842i, C846i Heart Rate Cables Upper...
  • Page 19 C842i, C846i Upright and Recumbent Cycle Troubleshooting the Junction Block 10. Remove the display housing per Procedure 7.13. Disconnect the upper interconnect cable from the upper PCA. 11. Disconnect the lower interconnect cable from the junction block. Connect the lower interconnect cable to the upper PCA.

  • Page 20: Procedure 6.2 - Troubleshooting The Keypad

    C842i, C846i Upright and Recumbent Cycle Procedure 6.2 - Troubleshooting the Keypad If the function keys on the electronic console are unresponsive, the problem may be either the upper PCA or keypad. This troubleshooting procedure gives you the information you need to determine which of these components is malfunctioning.

  • Page 21: Procedure 6.3 - Display Does Not Illuminate

    With the unit powered up, measure between test point 19 and test point 20 for approximately 8.5 Vdc. See Diagram 6.2. If the measurement is correct, skip to step 7. Diagram 6.2 - Lower PCA, C842i and C846i M1, M2...
  • Page 22 C842i, C846i Upright and Recumbent Cycle If the measurement in step 2 is significantly low or high, disconnect the interconnect cable from the J2 connector and repeat the measurement in step 4. If the measurement in step 2 is still significantly low or high, replace the lower PCA. If replacing the lower PCA does correct the problem, skip to step 9.

  • Page 23: Procedure 6.4 - No Or Incorrect Pedaling Resistance

    Disconnect the eddy current magnet wires from terminals M1 and M2 of the lower PCA. Measure between the eddy current magnet wires with an ohmmeter. It should read approximately 10 Ω. Diagram 6.3 - Eddy Current Magnet, C842i, C846i Generator Eddy...
  • Page 24 C842i, C846i Upright and Recumbent Cycle If the measurement in step 5 was correct, replace the lower PCA. It is highly unlikely that the RPM reading could every be present but incorrect. If this condition should occur, replace the lower PCA...

  • Page 25: Procedure 6.5 - Unit Does Not Mechanically Operate Freely/Quietly

    C842i, C846i Upright and Recumbent Cycle Procedure 6.5 - Unit does not Mechanically Operate Freely/Quietly Remove both covers per Procedure 7.1. If the unit is noisy, skip to step 8. If the unit does not turn freely continue with step 4.

  • Page 26: Procedure 6.6 - Troubleshooting Hand Held Heart Rate

    C842i, C846i Upright and Recumbent Cycle Procedure 6.6 - Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system, that is, it can accept a heart rate signal from either the hand held heart rate contacts on the unit’s handlebar or from a Polar heart rate chest strap transmitter.
  • Page 27 C842i, C846i Upright and Recumbent Cycle Set the on/off switch in the “off” position and remove the display housing. Verify the internal chest strap setting is set as shown in Diagram 6.7. Verify that a ferrite bead is installed on the heart rate PCA to upper PCA cable.
  • Page 28 C842i, C846i Upright and Recumbent Cycle 15. Set the on/off switch in the “off” position. Refer to Diagram 6.7 for the following measurements. With an ohmmeter measure between the “lower right contact” pin on the J1 connector and the lower right hand held heart rate contact on the handlebar. The reading should be 1 Ω...
  • Page 29 C842i, C846i Upright and Recumbent Cycle 25. Set the on/off switch in the “off” position, and remove the spare jumper from J14 of the heart rate PCA. Re-locate all potential sources of radiation. Set the on/off switch in the “on”...

  • Page 30: Procedure 7.1 - Removing Or Replacing One Or Both Covers

    C842i, C846i Upright and Recumbent Cycle Procedure 7.1 - Removing or Replacing One or Both Covers Remove four screws from the and left side of the top cover. Remove two screws from the rear of the cover and two screws from the bottom of the left and right covers.

  • Page 31: Procedure 7.2 - Replacing A Crankarm

    C842i, C846i Upright and Recumbent Cycle Procedure 7.2 - Replacing a Crankarm Grasp the pedal spindle with an open end wrench where it threads into the crankarm. The right hand pedal has normal threads and the left hand pedal has reverse threads. The Left hand pedal must be turned clockwise to loosen and counter-clockwise to tighten.

  • Page 32: Procedure 7.3 - Replacing The Seat Or Seat Post (Upright Cycle)

    C842i, C846i Upright and Recumbent Cycle Procedure 7.3 - Replacing the Seat or Seat Post (Upright Cycle) Loosen the seat mounting nut with a box or open end wrench. Lift the seat upward and off of the seat post. If you are not replacing the seat post, skip to step 4.

  • Page 33: Procedure 7.4 - Replacing All Or Part Of A Seat Carriage Assembly (Recumbent Cycle)

    C842i, C846i Upright and Recumbent Cycle Procedure 7.4 - Replacing All or Part of a Seat Carriage Assembly (Recumbent Cycle) There is a hand held heart rate cable the connects the seat carriage to the seat rail. Care must be taken when removing the seat carriage to avoid damaging the hand held heart rate cable.
  • Page 34 C842i, C846i Upright and Recumbent Cycle Diagram 7.4 - Hand Held Heart Rate Cable Seat Cable Seat Rail Cable Slide the seat rail cable back into the access hole. The seat carriage must travel over this cable, so it must be below the surface of the seat rail. Release the seat lever, hold the cable attached to the seat straight back from the seat as you slide the entire seat and seat carriage off of the rear of the seat rail.
  • Page 35 C842i, C846i Upright and Recumbent Cycle Diagram 7.6 - Seat Bottom Cable Cover Disconnect the external hand held heart rate cable from the internal hand held heart rate cable. If only the external cable is being replaced, skip to step 14. If the internal cable is being replaced continue with step 10.
  • Page 36 C842i, C846i Upright and Recumbent Cycle 12. Feed the wire ends out of the handlebars so that the black wire comes out of the top of the handlebars and the red wire comes out of the bottom of the handlebar.

  • Page 37: Procedure 7.5 - Replacing The Column

    C842i, C846i Upright and Recumbent Cycle Procedure 7.5 - Replacing the Column Remove the display housing per Procedure 7.12. While supporting the column, remove the two large bolts that fastens the lower portion of the column to the main frame. Carefully move the column away from the bike frame, taking care not to damage the cables shown in Diagram 6.2.

  • Page 38: Procedure 7.6 - Replacing The Upper Or Lower Interconnect Cable Or Heart Rate Cable

    C842i, C846i Upright and Recumbent Cycle Procedure 7.6 - Replacing the Upper or Lower Interconnect Cable or Heart Rate Cable Remove the display housing per Procedure 7.12. Disconnect the interconnect cable from J1 of the upper PCA or the heart rate cable from J4 of the hand held heart rate PCA.

  • Page 39: Procedure 7.7 - Replacing The Battery

    C842i, C846i Upright and Recumbent Cycle Procedure 7.7 - Replacing the Battery If the cycle is equipped with an external power adapter, disconnect the power adapter from the cycle. Remove left side cover. Disconnect the positive (red) and negative (black) wires from the battery. Remove the two screws that fasten the battery bracket to the frame.

  • Page 40: Procedure 7.8 - Replacing The Lower Pca

    C842i, C846i Upright and Recumbent Cycle Procedure 7.8 - Replacing the Lower PCA Disconnect the optional external power adapter, if equipped. Remove the left, right and top covers. Disconnect the red wire from the battery. Disconnect all of the wires from the lower PCA.

  • Page 41: Procedure 7.9 - Replacing The Display Housing Or Upper Pca

    C842i, C846i Upright and Recumbent Cycle Procedure 7.9 - Replacing the Display Housing or Upper PCA Remove the screws that retain the display, lift the display and disconnect the interconnect cable from the J5 connector and the heart rate cable from the J1 connector.

  • Page 42: Procedure 7.10 - Replacing The Primary Drive Belt

    Procedure 7.10 - Replacing the Primary Drive Belt Remove the right side cover. Loosen but do not remove the locknut retaining the idler pulley. See Diagram 7.9. This will remove tension from the primary belt. Diagram 7.9 - Primary Drive Belt, C842i, C846i Primary Pulley Primary...

  • Page 43: Procedure 7.11 - Replacing The Secondary Drive Belt

    Loosen the jam nuts on the secondary belt tension adjustment bolt. Loosen the adjustment bolt to remove tension from the secondary belt. See Diagram 7.10. remove the secondary belt. Diagram 7.10 - Secondary Drive Belt, C842i, C846i Secondary Belt Generator...

  • Page 44: Procedure 7.12 - Replacing The Primary Pulley Or Primary Bearings

    C842i, C846i Upright and Recumbent Cycle Procedure 7.12 - Replacing the Primary Pulley or Primary Bearings Remove the left, right and top covers. Remove the left and right crankarms per Procedure 7.2. Slide the left pulley cover off of the primary pulley axle.
  • Page 45 C842i, C846i Upright and Recumbent Cycle Procedure 7.13 - Replacing the Secondary Pulley, Intermediate Pulley or Secondary Bearings Remove the left, right and top covers. If only the secondary pulley is being replaced (the secondary pulley assembly contains the clutch bearing), skip this step and continue with step 16. Loosen the idler pulley locknut and release tension from the primary belt.
  • Page 46 C842i, C846i Upright and Recumbent Cycle 15. Route the secondary belt over the secondary pulley and the generator pulley. Tension the secondary belt per Procedure 5.2. 16. If necessary, route the primary belt around the primary pulley, over the idler pulley and around the secondary axle as shown in Diagram 7.9.

  • Page 47: Procedure 7.14 - Replacing The Idler Pulley

    C842i, C846i Upright and Recumbent Cycle Procedure 7.14 - Replacing the Idler Pulley Remove the right hand cover. Loosen the idler pulley locknut to remove tension from the primary belt. Then remove the idler pulley locknut. Remove the idler pulley from its mounting bolt.

  • Page 48: Procedure 7.15 - Replacing The Prom

    C842i, C846i Upright and Recumbent Cycle Procedure 7.15 - Replacing the PROM Anti-static kits (part number 20024-101) can be ordered from Precor. The PROM and the associated printed circuit assembly (PCA) are static sensitive. Anti- static devices must be used and all anti-static precautions must be followed during this procedure.

  • Page 49: Procedure 7.16 - Generator Replacement

    Remove all of the wiring from the lower PCA. Loosen the secondary belt adjustment belt to remove tension from the secondary belt. Remove the four generator mounting bolts. See Diagram 7.11 Diagram 7.11 - Generator Mounting C842i, C846i Lower PCA Generator...
  • Page 50 C842i, C846i Upright and Recumbent Cycle 11. Refer to Diagram 6.2 and replace the lower PCA wiring as follows. Connect the wires from the external power jack to connector J4 on the lower PCA. Connect the two red wires from the eddy current magnet to terminals M1 and M2 of the lower PCA (it does not matter which red wire goes on terminal M1 or M2).

  • Page 51: Procedure 7.17 - Primary Axle Or Bearing Replacement

    C842i, C846i Upright and Recumbent Cycle Procedure 7.17 - Primary Axle or Bearing Replacement Remove the left and right side covers. Remove both the left and right hand pedals. Refer to Procedure 7.2. Remove the screws that retain both the left and right hand crankarm covers. Remove both of the crankarm covers.
  • Page 52 If the left hand bearing requires replacement, replace it with Precor part number 45441-103. The right hand bearing is part of the primary pulley assembly. If the right hand bearing requires replacement, replace Precor part number 45439-102 primary pulley assembly.
  • Page 53 C842i, C846i Upright and Recumbent Cycle 12. Thread the 32 mm nut, removed in step 4, onto the left side of the primary axle and torque it 60 inch-pounds. 13. Route the primary belt around the primary pulley, over the idler pulley and around the secondary axle as shown in Diagram 7.9.
  • Page 54 C842i, C846i Upright and Recumbent Cycle Wiring Diagram 8.1 - C842i, C846i Page 54...
  • Page 55 C842i, C846i Upright and Recumbent Cycle Block Diagram 8.2 - C842i, C846i Page 55...

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C846i

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