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Precor C776i Manual

Precor C776i Manual

Precor c776i stairclimber manual
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C776i Stairclimber
C776i Stairclimber
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.
© 2005 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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  • Page 1 C776i Stairclimber 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. This section includes warning and caution statements, safety guidelines, and a list of required tools and equipment. It is highly recommended that you read this section, as well as the C776i Climber Owner’s Manual, before performing the maintenance procedures provided in this manual.

  • Page 3: Miscellaneous Information

    Anti-Static Handling Procedures The C776i Climbers contain some static-sensitive devices. Wrist straps dissipate static before it can damage static-sensitive devices you are servicing. Follow anti-static handling procedures and wear an anti-static device (such as a wrist strap) when you perform this procedure.

  • Page 4: Warning, Caution Statements And Safety Guidelines

    Warning, Caution Statements and Safety Guidelines WARNING and Caution statements are used throughout this manual to protect both you and the C776i Climber. Additional precautions and guidelines are provided to ensure your safety when servicing an C776i Climber. WARNING statements indicate a particularly dangerous activity. WARNING statements you will find in this manual include: •...
  • Page 5 C776i Stairclimber • Keep all electrical components, such as the power cord and the ON/OFF switch, away from water and other liquids. Page 5...

  • Page 6: Required Tools And Equipment

    C776i Stairclimber Required Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual. We recommend that you have this equipment available when you service C760 Series Climbers. TOOLS EQUIPMENT...

  • Page 7: Procedure 2.1 - Determining Software Version And Total Floors Climbed

    “powered up” condition, unless the climber is equipped with an optional external power supply. With the climber “powered up”, press keys RESET, 6, 5, sequentially. Diagram 2.1 - C776i Console Key 1 Key 4...
  • Page 8 C776i Stairclimber The message SOFTWARE VERSION will be displayed for two seconds and then UPPER APP XXXX-XXX. Press key to toggle display between the upper boot software version, lower software version and the upper app. software version. Press the ENTER key to continue to the error log.

  • Page 9: Procedure 2.2 - Performing Keypad And Display Diagnostics

    “powered up” condition, unless the climber is equipped with an optional external power supply. With the climber “powered up”, press keys RESET, 5, 1, 7, 6, 5, 7, 6, 1, sequentially. The C776i diagnostic software cycles through the following tests: • Display Test •...
  • Page 10 C776i Stairclimber The message BRAKE TEST will be displayed followed the power bit reading and SPM reading. This test allows you to test the brake (resistance) at each step rate level. Press the ENTER key to exit the diagnostics program.

  • Page 11: Procedure 2.3 - Selecting Club Settings

    C776i Stairclimber Procedure 2.3 - Selecting Club Settings Procedure Note: In order to perform this procedure the climber must remain in the “powered up” condition. It is necessary to use the climber in order to keep the climber in the “powered up” condition, unless the climber is equipped with an optional external power supply.

  • Page 12: 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 isolate 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 Service.

  • Page 13: Procedure 2.5 - Software Uploading Procedure

    If a palm device is to be used, the appropriate software must be available in the palm device. A PDA containing the appropriate software may be ordered from Precor or it may be downloaded to the PDA from your desktop or laptop computer via the “hot sync” function. With the PDA inserted in the hot sync cradle, download to “Precor IFP”...

  • Page 14: Section Three - Preventive Maintenance

    Regular Preventive Maintenance (Owner) Cleanliness of the C776i Climbers and their operating environment will keep maintenance problems and service calls to a minimum. For this reason, Precor recommends that the following preventive maintenance schedule be followed. At the End of Each Day •...
  • Page 15 C776i Stairclimber • Check the LED’s mounted on the upper PCA and the function keys displayed on the electronic console by performing Procedure 2.2. • Visually examine all wires and check connectors and wire connections. Secure connections and replace wiring as necessary.
  • Page 16 Procedure Start “stepping” on the climber. When the Precor banner prompt appears, press QUICK START. Operate the climber 4–5 minutes. As you operate the climber: Concentrate on the resistance of the climber and the sound of the stair arm belts and return springs as you pedal.
  • Page 17 C776i Stairclimber THEN... OTHERWISE... Refer to Section XX. Continue with the next step. 10. Check the LED’s mounted on the upper PCA and the function keys displayed on the electronic console by performing Procedure 2.2. Page 17...

  • Page 18: Procedure 5.1 - Inspecting The Stairarm Belts

    C776i Stairclimber Procedure 5.1 - Inspecting the Stairarm Belts Remove the left and right hand cover sections per Procedure 7.1. Grasp the stairarm return spring and carefully remove it from its mounting peg. See Diagram 5.1. Diagram 5.1 - Stairarm Return Spring...

  • Page 19: Procedure 5.2 - Checking Drive Belt Tension

    C776i Stairclimber Procedure 5.2 - Checking Drive Belt Tension Remove the left hand, right hand and rear cover sections per Procedure 7.1 Place the belt tension gauge on the primary (wide) drive belt as shown in Diagram 5.2. The gauge should read approximately 100 pounds.
  • Page 20 C776i Stairclimber Diagram 5.3 - Generator Belt Tension Generator Mounting Bolt Page 20...

  • Page 21: Procedure 6.1 - Troubleshooting The Lower And Upper Data Cables And Mid-Point Connector

    Connect a known good data cable from the upper printed circuit assembly to the mid-point connector. If the C776i now functions correctly, replace the upper data cable per Procedure XX. If the C776i still functions incorrectly, replace the original upper data cable and continue with step...
  • Page 22 Troubleshoot those component per the appropriate troubleshooting procedure. 11. If all of the above test have been performed and the C776i is still not functioning correctly, call Precor technical. support.
  • Page 23 Keyboard Cable Use the C776i, if the ERROR 05 or STUCK KEY message is still being displayed, replace the upper printed circuit assembly per Procedure XX. If the ERROR 05 or STUCK KEY in no longer displayed replace the display front panel (keyboard) per Procedure XX.
  • Page 24 The easiest means of determining which of the three components is the cause, is the to replace them, one at a time, with a known good component. If all of the above test have been performed and the C776i is still not functioning correctly, call Precor technical. support.

  • Page 25: Procedure 6.3 - Upper Display Does Not Illuminate

    If the cables and mid-point connector tested good in step 5, replace the upper printed circuit assembly. If all of the above test have been performed and the C776i is still not functioning correctly, call Precor technical. support. Diagram 6.4 - Lower Printed Circuit Assembly...
  • Page 26 10. If the voltage measurements are still absent, replace the generator. If the voltage measurements are now present, replace the lower printed circuit assembly. 11. If all of the above test have been performed and the C776i is still not functioning correctly, call Precor technical. support.

  • Page 27: Procedure 6.4 - No Resistance

    If the voltage measurements are still absent, replace the generator. If the voltage measurements are now present, replace the lower printed circuit assembly. If all of the above test have been performed and the C776i is still not functioning correctly, call Precor technical. support.

  • Page 28: Procedure 6.5 - Troubleshooting Hand Held Heart Rate

    C776i Stairclimber Procedure 6.5 - Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system, that is, it can accept a Polar heart rate signal from either the hand held heart rate contacts on the unit’s handlebar or from a heart rate chest strap transmitter.
  • Page 29 C776i Stairclimber if a hand held signal is being accepted and a chest strap signal is not being accepted, verify that the chest strap is good by testing it with a heart rate test receiver. If the chest strap is good, replace the external chest strap receiver.
  • Page 30 C776i Stairclimber 11. If neither a chest strap signal or a hand held signal is being accepted, measure between the “ground” and “5 Vdc” pins on J2 for 5 Vdc. If 5 Vdc is present, replace the heart rate PCA.

  • Page 31: Procedure 7.1 - Replacing The Covers

    C776i Stairclimber Procedure 7.1 - Replacing the Covers There are four cover sections, left hand, right hand, front and rear. Left Hand Cover Section Removal Remove the three screws that fasten the left hand cover section to the front cover section.
  • Page 32 C776i Stairclimber Front Cover Section Replacement 14. The front section must be replaced before either the left hand or right hand cover sections can be replaced. 15. Set the front cover section in its mounting position. 16. Fasten the front cover section with the screws and spacers removed in step 11.

  • Page 33: Procedure 7.2 - Replacing The Upper Pca

    Set the display front panel in its mounting position on the display housing and fasten it with the four screws removed in step 1. Thoroughly test the C776i as described in Section Four. Page 33...

  • Page 34: Procedure 7.3 - Replacing The Prom

    C776i Stairclimber Procedure 7.3 - Replacing the PROM 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. Remove the printed circuit assembly per its associated procedure.

  • Page 35: Procedure 7.4 - Replacing The Keyboard (Display Front Panel)

    Set the display front panel in its mounting position on the display housing and fasten it with the four screws removed in step 1. Thoroughly test the C776i as described in Section Four. Page 35...

  • Page 36: Procedure 7.5 - Replacing The Lower Pca

    C776i Stairclimber Procedure 7.5 - Replacing the Lower PCA Follow anti-static handling procedures and wear an anti-static device (such as a wrist strap) when you perform this procedure. Remove the left hand and right hand cover sections per Procedure 1.
  • Page 37 C776i Stairclimber Connect the red, black and white wires from the generator to the 3 PHASE GEN IN terminals. These wires may be connected in any order. Connect the data cable to its connector on the lower printed circuit assembly.

  • Page 38: Procedure 7.6 - Replacing A Stairarm Belt

    C776i Stairclimber Procedure 7.6 - Replacing A Stairarm Belt Remove the left hand or right hand cover, as required, per Procedure 7.1. Grasp the stairarm return spring and carefully remove it from its mounting peg. See Diagram 5.1. Support the stairarm and remove the stairarm belt from both flanged pulleys and the HTD pulley.

  • Page 39: Procedure 7.7 - Replacing A Htd (Toothed) Pulley

    C776i Stairclimber Procedure 7.7 - Replacing a HTD (Toothed) Pulley Remove the left hand or right hand cover, as required, per Procedure 7.1. Grasp the stairarm return spring and carefully remove it from its mounting peg. See Diagram 5.1. Support the stairarm and remove the stairarm belt from both flanged pulleys and the HTD pulley.
  • Page 40 C776i Stairclimber Wrap the stairarm belt over the HTD pulley, behind and under the upper flanged pulley. Wrap the belt under an around the lower flanged pulley. Then lift the stairarm and hook the return spring on its mounting peg. Check the belt to ensure there are no twists in the belt. If there are remove the return spring from its mounting peg and rotate the return spring to remove any twist.

  • Page 41: Procedure 7.8 - Replacing A Flanged Pulley

    C776i Stairclimber Procedure 7.8 - Replacing a Flanged Pulley There are four flanged pulleys, two on either side. Remove the left hand or right hand cover, as required, per Procedure 7.1. Grasp the stairarm return spring and carefully remove it from its mounting peg. See Diagram 5.1.

  • Page 42: Procedure 7.9 - Replacing The Primary Sheave

    C776i Stairclimber Procedure 7.9 - Replacing the Primary Sheave Remove the left hand cover, right hand cover and rear cover per Procedure 7.1. Grasp one of the stairarm return springs and carefully remove it from its mounting peg. See Diagram 5.1.
  • Page 43 C776i Stairclimber 10. Set the replacement primary sheave inside the primary belt then set the primary sheave in its mounting position. Insert the four mounting bolts, removed in step 8 through the flanged bearing assembly and the frame. Hand start the four mounting nuts on the mounting bolts.

  • Page 44: Procedure 7.10 - Replacing The Secondary Sheave

    C776i Stairclimber Procedure 7.10 - Replacing the Secondary Sheave Remove the left hand cover, right hand cover and rear cover per Procedure 7.1. Using a pair of pliers, straighten the locking tabs on both secondary sheave adjusters. Remove both of the secondary sheave tension adjusters. See Diagram 7.7.

  • Page 45: Procedure 7.11 - Replacing The Primary Drive Belt

    C776i Stairclimber Procedure 7.11 - Replacing the Primary Drive Belt Remove the primary sheave per Procedure 7.9, steps 1-9. Remove the secondary sheave per Procedure 7.10, steps 2-4. Set the primary sheave inside the replacement primary belt then set the primary sheave in its mounting position.

  • Page 46: Procedure 7.12 - Replacing The Generator Belt

    C776i Stairclimber Procedure 7.12 - Replacing the Generator Belt Remove the secondary sheave per Procedure 7.10, steps 1-4. Remove the generator belt. Set the replacement generator belt on the secondary sheave along with the primary belt. Set the secondary sheave in it mounting position. Hand start both secondary sheave tension adjusters.

  • Page 47: Procedure 7.13 - Replacing A Vertical Handlebar Assembly

    C776i Stairclimber Procedure 7.13 - Replacing a Vertical Handlebar Assembly Remove the two (one each side) vertical handlebar mounting bolts. See Diagram 7.8. Diagram 7.8 - Vertical Handlebar Mounting Handle Handlebar Clamp Handlebar Vertical Clamp Nut Handlebar Vertical Handlebar Bolt While supporting the vertical handlebar, remove both handlebar clamp nuts.
  • Page 48 C776i Stairclimber Disconnect the hand held heart rate (HHHR) connectors. Remove the vertical handlebar assembly. Set the replacement vertical handlebar assembly on the left and right handlebars as shown in Diagram 7.9. Connect the hand held heart rate (HHHR) connectors.

  • Page 49: Procedure 7.14 - Replacing The Right Or Left Handlebar

    C776i Stairclimber Procedure 7.14 - Replacing the Right or Left Handlebar Loosen but do not remove the two handlebar clamp nuts. See Diagram 7.8. Remove the bolt retaining the frame end cap. Remove the frame endcap and slide the handlebar boot up to expose the handlebar mounting bolt, See Diagram 7.10 Diagram 7.10 - Lower Handlebar Mounting...

  • Page 50: Procedure 7.15 - Replacing A Stairarm Foot Plate

    C776i Stairclimber Procedure 7.15 - Replacing a Stairarm Foot Plate Remove the left hand or right hand cover, as required, per Procedure 7.1. Grasp the stairarm return spring and carefully remove it from its mounting peg. See Diagram 5.1. Support the stairarm and remove the stairarm belt from both flanged pulleys and the HTD pulley.
  • Page 51 C776i Stairclimber Wrap the stairarm belt over the HTD pulley, behind and under the upper flanged pulley. Wrap the belt under an around the lower flanged pulley. Then lift the stairarm and hook the return spring on its mounting peg. Check the belt to ensure there are no twists in the belt. If there are remove the return spring from its mounting peg and rotate the return spring to remove any twist.

  • Page 52: Procedure 7.16 - Replacing A Stairarm

    C776i Stairclimber Procedure 7.16 - Replacing a Stairarm Remove the stairarm foot plate per Procedure 7.15, steps 1-3. Remove the retaining clip and the black plastic washer from the stairarm being replaced. See Diagram 7.12. Diagram 7.12 - Stairarms Bumper...

  • Page 53: Procedure 7.17 - Replacing A Generator

    C776i Stairclimber Procedure 7.17 - Replacing a Generator Remove the left hand cover per Procedure 7.1. Attach the wrist strap to your arm, then connect the ground lead of the wrist strap to the climber frame. Disconnect all of the wiring from the lower printed circuit assembly See Diagram 7.13.
  • Page 54 C776i Stairclimber Remove the four bolts that fasten the generator to the frame. See Diagram 7.15. Diagram 7.15 - Generator Mounting Mounting Bolt Remove the generator belt from the generator then remove the generator from the climber. Set the replacement generator at its mounting position. Hand start, but do not tighten the four generator mounting bolts removed in step 6.
  • Page 55 C776i Stairclimber 17. Replace the left hand cover per Procedure 7.1. 18. Check the C776i per Section Four. Page 55...

  • Page 56: Procedure 7.18 - Replacing A Battery

    Connect the red wire removed in step 2 to the battery terminal with the red dot. Connect the black lead to the remaining terminal of the battery. Replace the left hand cover per Procedure 7.1. Test the C776i per Section Four. Page 56...

  • Page 57: Procedure 7.19 - Replacing A Display Column

    C776i Stairclimber Procedure 7.19 - Replacing a Display Column Remove the left hand, right hand and rear covers per Procedure 7.1. Remove the left and right handlebars per Procedure 7.14, steps 1-5. Remove the vertical handlebar per Procedure 7.13, steps 1-3. Remove the handlebar clamp.
  • Page 58 C776i Stairclimber Diagram 7.18 - Display Housing Mounting Display Housing Mounting Screw 11. Set the display housing near the upper end of the replacement display column and feed the heart rate cable into the display housing and out of its access hole where the vertical handlebars will mount, See Diagram 7.9.
  • Page 59 26. Verify that both the left and right hand handlebars are fully inserted in the handlebar clamp. Securely tighten both handlebar clamp nuts. Then tighten both vertical handlebar bolts. 27. Replace the left hand, right hand and rear covers per Procedure 7.1. 28. Test the C776i per Section Four. Page 59...

  • Page 60: Wiring Diagram 8.1 - C776I

    C776i Stairclimber Wiring Diagram 8.1 - C776i UPCA Keyboard HHHR PCA 3 Phase Gen In Generator LPCA Load Magnet Bat+ Battery Bat- Page 60...

  • Page 61: Block Diagram 8.2 - C776I

    C776i Stairclimber Block Diagram 8.2 - C776i Page 61...

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