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Precor C844 User Manual

Upright cycle
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C844 Upright Cycle
C844 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.
© 2003 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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Summary of Contents for Precor C844

  • Page 1 C844 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 C844, facing the display enclosure. Warning and Caution Statements and General Safety Guidelines Warning statements indicate a particularly dangerous activity.

  • Page 3: General Information

    C844 Upright Cycle and checking the C844. • When operating the C844, do not wear loose clothing. Do not wear shoes with heels or leather soles. Check the soles of your shoes and remove any embedded stones. Tie long hair back.

  • Page 4: Required Tools And Equipment

    C844 Upright Cycle Required Tools and Equipment The following is a summary of the tools and equipment that may be required when you service a Precor C844 Upright Cycle. Tools Phillip and flat-head screwdrivers Standard and metric allen wrench set...

  • Page 5: Procedure 2.1 - Performing C844 Cycle Diagnostics

    Keypad Test Plug the power cord into the wall outlet, then turn on the cycle with the ON/OFF switch. With the PRECOR C844 banner scrolling, press the STOP, WORK LEVEL UP and WORK LEVEL DOWN keys simultaneously. Verify that the entire left display window illuminates, then two diagonal lines sweep across the display.
  • Page 6 C844 Upright Cycle Make a note of the Baseline Resistance numbers displayed on the electronic console. Individually press the WORK LEVEL keys and verify that the Baseline Resistance numbers change as the WORK LEVEL keys are pressed. The software version number is displayed on the electronic console. Press ENTER, then release.
  • Page 7 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 LEVEL UP to return to the PRECOR C844 banner. Page 7...

  • Page 8: Procedure 2.2 - Displaying The Odometer

    Plug the power cord into the wall outlet, then turn on the bike with the circuit breaker. With the PRECOR C844 banner scrolling, press the STOP and WORK LEVEL UP keys simultaneously and hold them until the message CYCLE ODOMETER scrolls across the left display window.

  • Page 9: Procedure 2.3 - Selecting Club Settings

    Plug the power cord into the wall outlet, then turn on the cycle with the ON/OFF switch. With the PRECOR C844 banner scrolling, press the QUICKSTART and WORK LEVEL keys simultaneously. Across the left display window scrolls either the banner U. S.
  • Page 10 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. Press ENTER, then release to return to the C844 Cycle banner. Page 10...

  • Page 11: Procedure 2.4 - Documenting Software Problems

    When a problem is found with either the software or upper or lower PCA’s, record the information listed below. 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 Customer Support.

  • Page 12: Section Three - Preventive Maintenance

    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.
  • Page 13 When the PRESS ENTER FOR PROGRAMS prompt appears, press QUICK START. Select Work Level 1 and press ENTER. Operate the C844 for 4–5 minutes. As you operate the cycle, concentrate on the resistance and operating sounds of the unit. Be on the alert for unusual rubbing, hitting, grinding or squeaking noises.

  • Page 14: Procedure 5.1 - Inspecting And Adjusting The Gap Between The Magnets And Flywheel

    Procedure 5.1 - Inspecting and Adjusting the Gap Between the Magnets and Flywheel 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. Procedure Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.
  • Page 15 C844 Upright Cycle Diagram 5-1 Adjusting the gap between the flywheel and magnet assembly Page 15...

  • Page 16: Procedure 5.2 - Measuring The Resistance Of A Magnet

    C844 Upright Cycle Procedure 5.2 - Measuring the Resistance of a Magnet 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. Procedure Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.
  • Page 17 C844 Upright Cycle Diagram 5.2 C844 Magnet Wiring Page 17...

  • Page 18: Procedure 5.3 - Inspecting And Adjusting The Gap Between Upper And Lower Couplers

    Procedure 5.3 - Inspecting and Adjusting the Gap Between Upper and Lower Couplers 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. Procedure Remove the upright covers from the pedestal weldment.
  • Page 19 C844 Upright Cycle Diagram 5.3 The Upper and Lower Couplers Page 19...

  • Page 20: Procedure 6.1 - Troubleshooting The Lower And Upper Ribbon Cables

    Procedure 6.1 - Troubleshooting the Lower and Upper Ribbon Cables 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. Troubleshooting the Upper Ribbon Cable Remove the upright covers from the pedestal weldment.
  • Page 21 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.

  • Page 22: Procedure 6.2 - Troubleshooting The Keypad And Upper Pca

    C844 Upright Cycle Procedure 6.2 - Troubleshooting the Keypad and Upper PCA 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 23 C844 Upright Cycle Table 6.1 - Voltage Test Points (Function Keys Not Pressed) Place the positive lead of the The voltmeter should read... voltmeter on... Pin 3 of J3 5 Vdc ± 500 mVdc Pin 7 of J3 5 Vdc ± 500 mVdc Pin 8 of J3 5 Vdc ±...

  • Page 24: Procedure 6.3 - Display Does Not Illuminate (120 Vac Units)

    Plug the AC line cord into the C844 AC input module. Plug the AC line cord into AC wall outlet. Using an AC voltmeter, check the AC voltage between the brown and blue wires on the AC input module.
  • Page 25 C844 Upright Cycle 10. Using a DC voltmeter, measure the voltage between terminals 1 and 26 of the ribbon cable connector (J2) on the upper PCA. The voltage should measure 6 VDC ± .25 VDC. If the DC voltage is incorrect or missing, check the ribbon cable connections at the lower and upper PCA’s.

  • Page 26: Procedure 6.4 - Display Does Not Illuminate (240 Vac Units)

    Plug the AC line cord into the C844 AC input module. Plug the AC line cord into AC wall outlet. Using an AC voltmeter, check the AC voltage between the brown and blue wires on the AC input module.
  • Page 27 C844 Upright Cycle connector (J2) on the upper PCA. The voltage should measure 6 VDC ± .25 VDC. If the DC voltage is incorrect or missing, check the ribbon cable connections at the lower and upper PCA’s. Check the ribbon cable for cut or frayed wires. If necessary replace the ribbon cable.

  • Page 28: Procedure 6.5 - The Rpm Display Is Incorrect

    If the voltage does not toggle, replace the reed switch. Test the C844 as in step 1, if the RPM reading is still 0, call Precor customer support. If the RPM reading is significantly high or low, proceed with step 5.

  • Page 29: Procedure 6.6 - No Or Incorrect Pedaling Resistance

    Note: The C844 will time out and remove power from the magnets in a short period of time. Slowly rotate the flywheel while taking the magnet voltage reading (step 3) to ensure that the C844 has not timed out.
  • Page 30 Anti-static kits (part number 20024-101) can be ordered from Precor. 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. Remove the screws that secure the upper display module assembly to the upper frame member.
  • Page 31 11. Position the upper display module on the upper frame member. Install the screws that secure the display module to the upper frame member. 12. Remove the ground lead of the wrist strap from the C844 frame, then remove the wrist strap from your arm.

  • Page 32: Procedure 7.2 - Replacing The Prom

    CAUTION When you perform the next step, tape the ribbon cable to the C844 to prevent it from falling into the upper frame member. Attach the wrist strap to your arm, then connect the ground lead of the wrist strap to the C844 frame.
  • Page 33 11. Connect the ribbon cable to the upper PCA. 12. Turn the 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.
  • Page 34 C844 Upright Cycle 20. Remove the ground lead of the wrist strap 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.

  • Page 35: Procedure 7.3 - Replacing The Lower Pca

    Procedure 7.3 - Replacing the Lower PCA 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.
  • Page 36 C844 Upright Cycle Diagram 7-3 C844 Wiring Diagram (120Vac Units) Page 36...

  • Page 37: Procedure 7.4 - Replacing The On/Off Switch

    Procedure 7.4 - Replacing the ON/OFF Switch 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.

  • Page 38: Procedure 7.5 - Replacing The Ac Input Module

    Procedure 7.5 - Replacing the AC Input Module 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.

  • Page 39: Procedure 7.6 - Replacing The Input Filter Assembly (240-Volt Units Only)

    Units Only) 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.

  • Page 40: Procedure 7.7 - Replacing The Upper And Lower Ribbon Cables

    Before you install a new ribbon cable, ensure that the ribbon 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. Remove the upright covers from the pedestal weldment.
  • Page 41 Continue with the next step. Skip to Step 13. 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 lower end of the old lower ribbon cable.

  • Page 42: Procedure 7.8 - Replacing The Pedals

    Procedure 7.8 - Replacing the Pedals 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. Use an open-end wrench to remove the right pedal from the crank arm.

  • Page 43: Procedure 7.9 - Replacing A Crank Arm

    If you are removing a crank arm, do not remove the pedal unless the pedal is worn or damaged and must be replaced. 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. Using the flat-head screwdriver, remove the crank axle dress cap.

  • Page 44: Procedure 7.10 - Replacing The Gear Box

    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. Remove the upright covers from the pedestal weldment (see Diagram 7-6).
  • Page 45 C844 Upright Cycle Position the coupler on the new gear box until the coupler is flush with the top of the shaft (see Diagram 7-7). Position the square key in the coupler. Replace the set screw that secures the coupler to the gear box. Push the rubber disk onto the coupler pegs.

  • Page 46: Procedure 7.11 - Replacing The Flywheel

    Procedure 7.11 - Replacing the Flywheel 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.

  • Page 47: Procedure 7.12 - Replacing The Upper Or Lower Couplers

    Procedure 7.12 - Replacing the Upper or Lower Couplers 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. Remove the upright covers from the pedestal weldment.
  • Page 48 C844 Upright Cycle IMPORTANT When you position the gear box, the couplers must line up (see Diagram 7-8). 13. Install the bolts that secure the gear box to the pedestal weldment. 14. Inspect and adjust the gap between the upper and lower couplers as described in Procedure 5.3.

  • Page 49: Procedure 7.13 - Replacing A Magnet Assembly

    Procedure 7.13 - Replacing a Magnet Assembly 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.
  • Page 50 C844 Upright Cycle Diagram 7-10 Flywheel and Magnet Assembly Position the new magnet assembly on the cycle. Note: When you mount the magnet assembly, do not tighten the mounting hardware securely until you have adjusted the gap between the flywheel and the magnet assembly.

  • Page 51: Procedure 7.14 - Replacing The Transformer

    Procedure 7.14 - Replacing the Transformer 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.

  • Page 52: Procedure 7.15 - Replacing The Reed Switch

    Procedure 7.15 - Replacing the Reed Switch 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. Place the C844 Cycle on its front end. Remove the pan from the base of the cycle.

  • Page 53: Procedure 7.16 - Replacing The Seat Detent Pin And Spring

    Procedure 7.16 - Replacing the Seat Detent Pin and Spring 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. Pull and hold the detent pin out of the seat pin housing. Remove the seat post assembly and seat from the cycle frame.

  • Page 54: Procedure 7.17 - Replacing The Handlebar Assemblies

    Procedure 7.17 - Replacing the Handlebar Assemblies 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. Remove the bolts that secure the handlebar assemblies to the handlebar clamps.

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