C762, C764, C764i Stairclimber C762, C764, C764i 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.
C762, C764, C764i Stairclimber Section One - Things You Should Know About This Manual This manual is written for you, the C760 Series Climber service technician. The objective of this service manual is to provide you with the instructions you need to maintain, inspect and adjust C760 Series Climbers, troubleshoot malfunctions, and remove and replace components. This manual includes the sections and appendices described in the following paragraphs. Section One, Things You Should Know.
C762, C764, C764i Stairclimber Miscellaneous Information Right, Left, Front, and Back Conventions In this manual, right, left, front, and back are from the perspective of a user standing on the climber, facing the display enclosure. Anti-Static Handling Procedures The C760 Series Climbers contain some static-sensitive devices. Wrist straps dissipate static before it can damage static-sensitive devices you are servicing.
C762, C764, C764i Stairclimber Version A and Version B Disk Assemblies Diagram 1-2 shows the Version A and Version B disk assembly shafts. The Version B disk assembly shaft has shoulders, the Version A disk assembly shaft does not. The Version A and Version B disk assemblies are interchangeable. The part number for the Version A disk assembly is 36020-101. 36020-102 is the part number for the Version B disk assembly. Diagram 1.
C762, C764, C764i Stairclimber Warning, Caution Statements and Safety Guidelines WARNING and Caution statements are used throughout this manual to protect both you and the C760 Series Climber. Additional precautions and guidelines are provided to ensure your safety when servicing an C760 Series Climber. WARNING statements indicate a particularly dangerous activity.
C762, C764, C764i Stairclimber • Be aware that the weight limit for the C760 Series Climber is 350 pounds. • Keep all electrical components, such as the power cord and the ON/OFF switch, away from water and other liquids.
C762, C764, C764i 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.
C762, C764, C764i Stairclimber Eddy Current Resistance and the C760 Series Climber Magnetism When the disk rotates, it “cuts” the lines of force that make up the magnetic field. As the lines of force are cut, voltage is induced in the disk. The current produced by this induced voltage is called eddy current. How Eddy Current Works Current flowing through a conductor produces a magnetic field.
C762, C764, C764i Stairclimber Procedure 2.1 - Determining Software Version and Total Floors Climbed Software version numbers are invaluable for tracking and identifying problems and staying aware of changes to the operation and features of the product. Units manufactured after May 28, 2000 (software version 6.20) Utilize standard access codes. See Diagrams 2.1 and 2.2 for key number assignments. Procedure 1. Plug the power cord into the wall outlet, then turn on the climber with the ON/OFF switch. 2.
C762, C764, C764i Stairclimber Diagram 2.1 - C762 Stairclimber Display Key #2 Key #3 Key #1 Key #5 Key #7 Key #6 Diagram 2.
C762, C764, C764i Stairclimber Procedure 2.2 - Performing Keypad and Display Diagnostics Procedure 1. Plug the power cord into the wall outlet, then turn on the climber with the ON/OFF switch. 2. Units manufactured after May 28, 2000 (software version 6.20) Utilize standard access codes. See Diagrams 2.1 and 2.2 for key number assignments. 3.
C762, C764, C764i Stairclimber THEN... The keypad test is successful; continue with the next step. 8. OTHERWISE... Go to Step 3 of Procedure 6.2. Press RESET. The message KEY PRESSED PLEASE WAIT is momentarily displayed on the electronic console. When the PRESS ENTER FOR PROGRAMS prompt is displayed, continue with the next step.+ Note: The keys on the left keypad are the RESET keys and two hidden keys. The two hidden keys are called 'hidden key next to reset' and 'left most hidden key'. Table 2.
C762, C764, C764i Stairclimber Procedure 2.3 - Selecting Club Settings Procedure 1. Plug the power cord into the wall outlet, then turn on the climber with the ON/OFF switch. 2. Units manufactured after May 28, 2000 (software version 6.20) Utilize standard access codes. See Diagrams 2.1 and 2.2 for key number assignments. 3.
C762, C764, C764i Stairclimber 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.
C762, C764, C764i Stairclimber Section Three - Preventive Maintenance Preventive maintenance measures are either scheduled (performed on a regular basis by the owner) or unscheduled (performed when you make a service call). Maintenance performed by the owner is limited to cleaning and visually inspecting the climber and making the adjustments specified in the C760 Series Owner's Manual.
C762, C764, C764i Stairclimber • • Check the LEDs mounted on the upper PCA and the function keys displayed on the electronic console by performing Procedure 2.2. Measure the gaps between the disk and the magnet assemblies as described in Procedure 5.1. • Visually examine all wires and check connectors and wire connections. Secure connections and replace wiring as necessary.
C762, C764, C764i Stairclimber Section Four - Checking Unit Operation This section provides you with a method of checking climber operation. Check climber operation at the end of a maintenance procedure and when it is necessary to ensure that the climber is operating properly. Procedure 1. Plug the power cord into the wall outlet, then turn on the climber by using the circuit breaker. 2. When the PRESS ENTER FOR PROGRAMS prompt appears, press QUICK START. 3. Select Work Level 1 and press ENTER. 4.
C762, C764, C764i Stairclimber 9. If the climber resistance does not change or the climber operation feels inconsistent compared with Work Levels 1 and 5... THEN... Refer to Section 6. OTHERWISE... Continue with the next step. 10. Check the LEDs mounted on the upper PCA and the function keys displayed on the electronic console by performing Procedure 2.2. 11. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet.
C762, C764, C764i Stairclimber Procedure 5.1 - Inspecting and Adjusting the Gaps Between the Disk and the Magnet Assemblies Procedure 1. Remove the covers as described in Procedure 7.1. WARNING Before performing maintenance operations with the covers removed, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Press down the stairarm with one hand. With your other hand, grasp and pull the end of the stairarm belt connected to the return spring.
C762, C764, C764i Stairclimber 4. If the .050 feeler gauge does not fit snugly... THEN... Continue with the next step. 5. OTHERWISE... Skip to Step 7. Barely loosen the bolts, lock washers, and flat washers that secure the right magnet assembly to the climber frame (see Diagram 5.2). Diagram 5.2 - Magnet Assemblies Disk Assembly Magnet Assemblies Cable Clamp Note: Do not loosen the bolts too much.
C762, C764, C764i Stairclimber along the adjustment slots, the assembly must stay in place after it is moved. 6. Slide the top part of the magnet assembly along its adjustment slot until the .050 feeler gauge fits snugly between the disk and the top coil on the assembly. 7. Place the .050 feeler gauge between the disk and the lower coil on the right magnet assembly. Choose one: IF... The .050 feeler gauge does not fit snugly THEN... Continue with Step 9 The .
C762, C764, C764i Stairclimber Procedure 5.2 - Measuring the Resistance of the Magnet Assemblies Caution Remove power from the climber before you measure magnet resistance. Procedure 1. Remove the covers as described in Procedure 7.1. WARNING Before performing maintenance operations with the covers removed, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Press down the stair arm with one hand.
C762, C764, C764i Stairclimber Diagram 5.
C762, C764, C764i Stairclimber Procedure 6.1 - Troubleshooting the Lower and Upper Ribbon Cables Fault Isolating the Lower Ribbon Cable 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section Nothings you Should Know. 2. Using the screwdriver, remove the two screws that secure the power entry module to the climber frame. Pull the module out of the climber.
C762, C764, C764i Stairclimber Diagram 6.1 - Upper and Lower Ribbon cables 12. Disconnect the ribbon cable from the upper PCA. 13. Connect the spare ribbon cable between the upper PCA and the lower ribbon cable connector. 14. Connect the original lower ribbon cable to the lower PCA. 15. Check the operation of the climber as described in Section Four. 16. Disconnect the spare ribbon cable from the Upper PCA and the lower ribbon cable. 17.
C762, C764, C764i Stairclimber THEN... The original upper ribbon cable is bad; install a new cable as described in Procedure 7.10. OTHERWISE... The original upper ribbon cable is not bad; continue with the next step. 18. Support the display housing while you connect the original upper ribbon cable to the upper PCA. 19. Connect the original upper and lower ribbon cables to each other. 20. Line up the tabs on the display housing with the tab holes on the display base plate. 21.
C762, C764, C764i Stairclimber 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. Procedure 1. Set the circuit breaker in the “off” position.
C762, C764, C764i Stairclimber Diagram 6.3 - Upper PCA Component Layout Table 6.1 - Voltage Test Points (Function Keys Not Pressed) PLACE THE POSITIVE LEAD OF THE VOLTMETER ON... Pin 1 of J4 Pin 2 of J4 Pin 3 of J4 Pin 4 of J4 Pin 6 of J4 Pin 7 of J4 Pin 8 of J4 Pin 9 of J4 Pin 4 of J2 THE VOLTMETER SHOULD READ... 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc 5 Vdc ± 500 mVdc Table 6.
C762, C764, C764i Stairclimber 8. If the voltage readings in Table 6.1 are incorrect, disconnect the keypad cable from the key pad connector and repeat the voltage measurements in 6.1. If the voltage readings are now correct, replace the display housing (keypad). If the voltage readings are still incorrect, replace the upper PCA. 9. If the voltage readings in Table 6.1 are correct and one or more voltage readings in Table 6.2 are incorrect, replace the display housing (keypad). 10.
C762, C764, C764i Stairclimber Procedure 6.3 - Upper Display Does Not Illuminate Warning Hazardous voltages will be tested in the following procedure. Exercise extreme caution when performing these procedures. Do not connect or disconnect any wiring, connectors or other components with power applied to the treadmill. 1. Disconnect the line cord from the AC wall outlet. Using an AC voltmeter, verify that the proper AC voltage is present at the wall outlet.
C762, C764, C764i Stairclimber 9. Refer to block diagram 8.2 and note the ribbon cable connections for “+6V” and “ground”. Set treadmill circuit breaker in the “off” position. Remove the upper PCA from the display housing. With the ribbon cable still connected, set the upper PCA on an insulated surface. Set circuit breaker in the “on” position. Using a DC voltmeter, measure the voltage between the “+6v” and “ground” connections on the ribbon cable connector on the upper PCA.
C762, C764, C764i Stairclimber Procedure 6.4 - No Resistance Note: The term resistance in this case refers to the physical opposition to the downward movement of the stairarm. That is, the greater the resistance, the slower fall rate and the lesser the resistance the faster the fall rate. Note: If the stairclimber is unused for 30 seconds, power is removed from the magnets.
C762, C764, C764i Stairclimber 5. If the voltage in step 4 is 0 Vac or very low, check that the three light emitting diodes on the lower PCA are lit. If the display is illuminated and one of the three LED’s is not lit, replace the lower PCA. 5. If the display is not illuminated, go to procedure 6.3. 6. If you have performed all of the previous procedures and are unable to locate the problem, contact Precor Customer Support.
C762, C764, C764i Stairclimber Procedure 6.5 - Troubleshooting the Speed Sensor Note: If the stairclimber is unused for 30 seconds, power is removed from the magnets. The stairclimber senses that it is being used by monitoring the speed sensor output. 1. Set the circuit breaker in the “on” position and enter the manual program. 2. Using a voltmeter, measure the voltage between the orange and brown wires on the speed sensor. The voltage should be approximately 12 Vdc.
C762, C764, C764i Stairclimber 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 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. Refer to Diagram 6.4 and verify the J9, J10, J11 and J12 jumper settings. J10 and J11 should be jumpered. J9 and J12 should be open (as shown in Diagram 6.4).
C762, C764, C764i Stairclimber 3. 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. If the heart rate test receiver does not accept a signal from the chest strap, replace the chest strap. 4. Replace the jumper on J10 (removed in step 1). No hand held reading - Normal chest strap reading 5.
C762, C764, C764i 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. 12. If 5 Vdc is not present, remove the connector from J2 of the heart rate PCA. Measure between the “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.
C762, C764, C764i Stairclimber Procedure 7.1 - Replacing the Covers Removing the Covers 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. 2. Slide the collar up on the column. 3. Choose one: 4. IF... You are removing the left cover THEN... Remove the screws that secure the power entry module to the climber frame. Pull the module out of the climber, then continue with the next step.
C762, C764, C764i Stairclimber Diagram 7.1 - Cover Mounting Replacing the Covers When you replace the covers, install the screw on the cover bracket first. 8. 9. Choose one: IF... You are replacing the left cover THEN... Continue with the next step You are replacing the right cover only Skip to Step 12 Position the left cover against the climber frame.
C762, C764, C764i Stairclimber Note: Take care not to pinch the cables when you perform the next step. 10. Push the power entry module into the climber. Install the screws that secure the power entry module to the climber frame. 11. Install the screws that secure the left cover to the climber frame. 12. Position the right cover against the climber frame; install the screws that secure the right cover to the climber frame. 13. Tighten the fasteners that secure the top of the cover to the climber frame.
C762, C764, C764i Stairclimber Procedure 7.2 - Replacing the Upper PCA Use anti-static handling procedures and wear an anti-static device (such as a wrist strap) when you perform this procedure. Anti-static kits can be ordered from Precor Customer Service (Precor part number 20024-101). Removing the Upper PCA 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet.
C762, C764, C764i Stairclimber Replacing the Upper PCA 9. Carefully connect the keypads to the upper PCA. 10. Position the upper PCA over the plastic mounting tabs on the display housing. 11. Push the upper PCA onto the plastic mounting tabs. Press down the upper PCA until the edge of the PCA is held by the tabs. 12. Connect the upper ribbon cable to the upper PCA. 13. Remove the ground lead of the wrist strap from the climber frame, then remove the wrist strap from your arm. 14.
C762, C764, C764i Stairclimber Procedure 7.3 - Replacing the PROM Anti-static kits (part number 20024-101) can be ordered from Precor. 1. The PROM and the associated printed circuit assembly (PCA) are static sensitive. Antistatic devices must be used and all anti-static precautions must be followed during this procedure. 2. Remove the printed circuit assembly per its associated procedure. 3. Currently we are using two styles of IC software packages.
C762, C764, C764i Stairclimber Procedure 7.4 - Replacing the Power Cable Harness Removing the Power Cable Harness 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Note: Take care not to damage the cables when you perform the next step. 1. Remove the screws that secure the power entry module to the climber frame.
C762, C764, C764i Stairclimber Diagram 7.3 - Power Entry Wiring Replacing the Power Cable Harness 7. Push the power cord into the round hole on the front of the power entry module. Make sure that the power cord connectors can reach the ground stud and circuit breaker. 8. Place the strain relief around the power cable insulation that is next to the outside of the power entry module. 9.
C762, C764, C764i Stairclimber 13. Connect the remote sensor cable and the magnet harness to the lower PCA. 14. Place the ground cable assembly and the ground wires attached to the input filter assembly and power cord on the power entry module ground stud. Install the nut that secures the wires on the ground stud. Note: Take care not to pinch the cables when you perform the next step. 15. Push the power entry module into the climber.
C762, C764, C764i Stairclimber Procedure 7.5 - Replacing the Lower PCA Removing the Lower PCA 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Note: Take care not to damage the cables when you perform the next step. 2. Remove the fasteners that secure the power entry module to the climber frame.
C762, C764, C764i Stairclimber Procedure 7.6 - Replacing the Circuit Breaker Removing the Circuit Breaker 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Note Take care not to damage the cables when you perform the next step. 2. Remove the fasteners that secure the power entry module to the climber frame.
C762, C764, C764i Stairclimber Diagram 7.
C762, C764, C764i Stairclimber Procedure 7.7 - Replacing the Line Filter Removing the 1. Line Filter Assembly Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Note: Take care not to damage the cables when you perform the next step. 2. Remove the screws that secure the power module to the climber frame.
C762, C764, C764i Stairclimber Replacing the Input Filter Assembly When you perform the next step, orientate the line filter assembly so that the side of the filter assembly with the green/yellow wire is nearest the power entry module ground stud. 10. Position the line filter assembly at its mounting location on the power entry module. Install the screws that secure the input filter assembly to the power entry module. 11.
C762, C764, C764i Stairclimber Procedure 7.8 - Replacing the Transformer Removing the Transformer 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Note: Take care not to damage the cables when you perform the next step. 2. Remove the screws that secure the power entry module to the climber frame.
C762, C764, C764i Stairclimber Procedure 7.9 - Replacing the Ground Cable Assembly There are three wires on the power entry module ground stud. Two of these wires are connected to the input filter assembly and the power cord. The third wire is the ground cable assembly. It is connected to the ground stud on the climber frame. Removing the Ground Cable Assembly 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet.
C762, C764, C764i Stairclimber Procedure 7.10 - Replacing the Lower and/or Upper Ribbon Cables Before you install a new ribbon cable, ensure that the ribbon cable is defective as described in Procedure 6.1, Troubleshooting the Lower and Upper Ribbon Cables. Removing the Lower Ribbon Cable 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet.
C762, C764, C764i Stairclimber Diagram 7.5 - Upper and Lower Ribbon Cables Upper Ribbon Cable Lower Ribbon Cable Note: The cable clips hold the lower ribbon cable away from moving components on the climber. Note how the lower ribbon cable is folded and routed through the cable clips. 10. Remove the lower ribbon cable from the cable clips mounted on the climber frame. Replacing the Lower Ribbon Cable 11. Gently feed one end of the ribbon cable down through the left column frame upright. 12.
C762, C764, C764i Stairclimber Note: Take care not to pinch the cables when you perform the next step. 15. Push the power entry module into the climber. Install the screws that secure the power entry module to the climber frame. 16. Install the screws that secure the left cover to the climber frame. 17. Tighten the fastener that secures the top of the left cover to the climber frame. 18. Position the front cover enclosure strip over the gap created by the right and left covers.
C762, C764, C764i Stairclimber 27. Gently press the display housing onto the display base plate until the tabs are pushed into the holes on the base plate. 28. Replace the screws that secure the display housing to the display base plate Note: Gently push any excess cable into the column. 29. Connect the upper and lower ribbon cables to each other. 30. Slide the enclosure collar down the column and over the column mounting screws. Press down to ensure a snug fit. 31.
C762, C764, C764i Stairclimber Procedure 7.11 - Replacing the Remote Sensor Assembly Removing the Remote Sensor Assembly 1. Remove the covers as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Remove the remote sensor cable from the lower PCA. Note: The cable clips hold the remote sensor cable away from moving components on the climber. 3.
C762, C764, C764i Stairclimber Diagram 7.
C762, C764, C764i Stairclimber Procedure 7.12 - Replacing the Magnet Cable Assembly Removing the Magnet Cable Assembly 1. Remove the right cover as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Remove the screw that secures the magnet cable in the cable clamp. 3. Remove the magnet cable assembly from the lower PCA. 4.
C762, C764, C764i Stairclimber Diagram 7.
C762, C764, C764i Stairclimber Procedure 7.13 - Replacing a Magnet Assembly Each magnet assembly consists of an upper and a lower magnet coil. Diagram 7.8 shows the magnet assemblies used on the C760 Series Climbers. Removing a Magnet Assembly 1. Remove the covers as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2.
C762, C764, C764i Stairclimber Replacing a Magnet Assembly Do not tighten the bolts more than finger tight when you perform the next step. 5. Position the magnet assembly against the frame upright (see Diagram 7.9). Install the fasteners that secure the magnet assembly to the frame upright. 6. If you are replacing only one magnet assembly... THEN... Continue with the next step. 7. OTHERWISE... Repeat Step 5 for the second magnet assembly; then continue with the next step.
C762, C764, C764i Stairclimber Note: The wires that make up the magnet cable assembly are pre-bent. When the magnet cable assembly is installed correctly, the wires will fit naturally around the magnet assemblies. 8. Push the blue wire connector onto the top terminal on the upper magnet coil. Push the red wire connector onto the top terminal on the lower magnet coil. Connect the ends of the yellow wire to the empty terminals on the magnet coils. Repeat this step if you replaced both magnet assemblies. 9.
C762, C764, C764i Stairclimber Procedure 7.14 - Replacing a Return Spring Removing the Return Spring If you are removing only one return spring, remove only one cover. It is not necessary to remove both covers unless you are removing both return springs. 1. Remove the cover necessary to access the return spring you are removing as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2.
C762, C764, C764i Stairclimber Replacing the Return Spring 5. Visually inspect the grommet for wear, cracks, or other damage. Replace the grommet if necessary. Note: Each spring bracket has two holes. Insert the spring into the outer hole on the bracket when you perform the next step (see Diagram 7.11). 6. Insert one end of the return spring in the spring bracket. Note: When you perform the next step, make sure that the end of the spring points down when you place it in the clamp. 7.
C762, C764, C764i Stairclimber 8. Lift the stair arm assembly from the frame weldment. Grasp the Stairarm belt and lift it over the toothed pulley. Route the belt under the idler pulley. 9. If you are replacing only one return spring... THEN... Continue with the next step. OTHERWISE... Repeat Steps 5 through 8 for the second spring; then continue with the next step. 10. Check the operation of the climber as described in Section Four, then replace the cover as described in Procedure 7.1.
C762, C764, C764i Stairclimber Procedure 7.15 - Replacing A Stairarm Belt Removing the Stairarm Belt If you are removing only one stairarm belt, remove only one cover. It is not necessary to remove both covers unless you are removing both stairarm belts. 1. Remove the cover necessary to access the stairarm belt you are removing as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2.
C762, C764, C764i Stairclimber Replacing the Stairarm Belt 7. Route one end of the stairarm belt through the front of the pedal (see Diagram 7.13). Diagram 7.13 - Routing the Stairarm Belt Stairarm Belt Stairarm 8. Place and hold the end of the belt against the belt clamp weldment on the underside of the pedal. The end of the belt should be flush with the end of the clamp. 9. Place the belt clamp against the belt positioned in the previous step.
C762, C764, C764i Stairclimber Diagram 7.14 - Underside of Stairarm Pedal Note: Hold the sides of the grooved belt clamp together when you perform the next step. 13. Install the fasteners that hold the sides of the grooved belt clamp together. 14. Place the return spring in the grooved belt clamp. Position the spring as shown in Diagram 7-14. 15. Lift the stair arm assembly from the frame weldment. Grasp the stairarm belt and lift it over the toothed pulley. Route the belt under the idler pulley 16.
C762, C764, C764i Stairclimber Procedure 7.16 - Replacing A Toothed Pulley Removing the Toothed Pulley If you are removing only one toothed pulley assembly, remove only one cover. It is not necessary to remove both covers unless you are removing both toothed pulleys. 1. Remove the cover necessary to access the toothed pulley you are removing as described in Procedure 7.1.
C762, C764, C764i Stairclimber Important There is text on one side of the toothed pulley. When you replace the right pulley, position the pulley on the sheave shaft so that the text faces you when you stand on the right side of the climber. When you install the left toothed pulley, position the pulley on the sheave shaft so that the text faces away from you when you stand on the left side of the climber. 8. Slide the toothed pulley onto the sheave shaft.
C762, C764, C764i Stairclimber 11. Lift the stairarm assembly from the frame weldment. Grasp the stairarm belt and lift it over the toothed pulley. Route the belt under the idler pulley. 12. If you are replacing only one toothed pulley... THEN... Continue with the next step. OTHERWISE... Repeat Steps 6 through 10 for the second pulley; then continue with the next step. 13. Check the operation of the climber as described in Section Four, then replace the cover as described in Procedure 7.1.
C762, C764, C764i Stairclimber Procedure 7.17 - Replacing An Idler Pulley Removing the Idler Pulley If you are removing only one idler pulley, remove only one cover. It is not necessary to remove both covers unless you are removing both idler pulleys. 1. Remove the cover necessary to access the idler pulley you are removing as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2.
C762, C764, C764i Stairclimber 10. Lift the stairarm assembly from the frame weldment. Grasp the stairarm belt and lift it over the toothed pulley. Route the belt under the idler pulley. 11. If you are replacing only one idler pulley... THEN... Continue with the next step. OTHERWISE... Repeat Steps 6 through 10 for the second idler; then continue with the next step. 12. Check the operation of the climber as described in Section Four, then replace the cover as described in Procedure 7.1.
C762, C764, C764i Stairclimber Procedure 7.18 - Replacing the Disk Assembly Diagram 1.2 shows the Version A and Version B disk assembly shafts. Version A and Version B disk assemblies are interchangeable. The part number for the Version A disk assembly is 36020-101. 36020-102 is the part number for the Version B disk assembly. You will need two 17mm open-end wrenches to remove and replace the Version A disk assembly.
C762, C764, C764i Stairclimber Diagram 7.16 - The Disk Assembly Disk Assembly Outer Nut Inner Nut Replacing the Disk Assembly 6. Push the disk assembly through the drive belt hanging from the sheave shaft. Position the belt against the disk hub and behind the drive belt idler as you slide the disk assembly into the disk brackets. Push the disk in as far as possible. Important Make sure that the remote sensor assembly tabs straddle the disk target (refer back to Diagram 7.6).
C762, C764, C764i Stairclimber 8. Thread a nut onto the longer side of the disk shaft. Using one of the 17mm open-end wrenches, hold the inner nut on the disk assembly. Using the second 17mm open-end wrench, tighten the outer nut that secures the disk assembly to the disk brackets. Repeat this step for the second side of the disk shaft. 9. Place the 0.030" feeler gauge between an inner nut and the disk assembly. 10. Choose one: IF... The .030 feeler gauge fits snugly THEN... Skip to Step 15 The .
C762, C764, C764i Stairclimber 17. Kneel behind the stair arms. Press down on the ends of the stair arms. Watch the drive belt as it moves on the sheave, drive belt idler, and disk hub. 18. Choose one: IF... The drive belt has a tracking problem THEN... Continue with the next step The drive belt tracks correctly Skip to Step 21 19. Remove the set screws that secure the sheave to the sheave shaft. Gently tap the sheave to re-position it on the sheave shaft. 20.
C762, C764, C764i Stairclimber Procedure 7.19 - Replacing the Sheave, Sheave Shaft or Sheave Bearings Removing the Sheave Assembly The sheave assembly consists of the sheave, the sheave shaft, and the bearing assemblies. 1. Remove the covers as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Press down a stairarm with one hand.
C762, C764, C764i Stairclimber Removing a Bearing From the Sheave Shaft Set the sheave assembly on a work bench or table when you perform the next step. 9. Remove the loose flange from the end of the sheave shaft (see Diagram 7.17). Remove the set screws that secure the bearing to the sheave shaft. Slide the bearing and second flange from the sheave shaft. Discard the bearing and set aside the set screws and flanges. If you are removing both bearings, repeat this step for the second bearing. 10.
C762, C764, C764i Stairclimber Replacing the Sheave On the Sheave Shaft Look at the key slot on the sheave assembly. The length of shaft to the right of the key slot is longer that the length of shaft to the left of the key slot. When you slide the sheave onto the shaft, make sure that the sheave hub faces the left end of the shaft. 13. Position the key in the key slot in the sheave shaft. Push the sheave shaft through the sheave so that the key is centered on the key slot in the sheave.
C762, C764, C764i Stairclimber Diagram 7.18 - The Sheave Assembly Sheave Assembly Idler Arm Hitch Pin Idler Pulley Clevis Pin Disk Assembly 20. Mount the drive belt on the sheave by performing the following sub-steps: a. Kneel on the right side of the climber and face the sheave. b. Hold the drive belt between the 12 o'clock and 3 o'clock positions on the sheave rim. c. Turn the sheave counterclockwise. Note: As you move the sheave, the belt will position itself on the rim. d.
C762, C764, C764i Stairclimber Note: Make sure that the belt is on the sheave rim before you continue with this procedure. Installing the Toothed Pulleys and Toothed Belts 21. Slide a thrust washer, the wave washer, and three more thrust washers onto one end of the sheave shaft. 21. Slide the toothed pulley and the remaining thrust washer onto the sheave shaft. Using the snap ring pliers, install the retaining ring next to the thrust washer. 21. Lift the stair arm assembly from the frame weldment.
C762, C764, C764i Stairclimber Note: The bearing flanges secure the sheave assembly to the climber frame. Install the sheave assembly to the climber frame as described in Steps 31 through 36. 28. Hold an outer flange next to the sheave bracket. Place bolts through the sheave bracket and flange. Repeat this step for the second outer flange. 29. Slide the bearing next to the outer flange. Hold the bearing in place. 30. Add a drop of blue loctite to the tip of two set screws.
C762, C764, C764i Stairclimber Procedure 7.20 - Replacing the Drive Belt Removing the Drive Belt 1. Remove the covers as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Loosen the drive belt by pushing down on the top of the drive belt idler arm. Hold the idler arm down while you pull the belt out of the sheave rim. Place the belt on the left end of the sheave shaft. 3.
C762, C764, C764i Stairclimber 12. Install the locknuts that secure the flanges to the sheave bracket. 13. Repeat Steps 11 and 12 for the flanges and bearing on the left end of the sheave shaft. 14. Stand at the back of the climber and face the disk assembly. The drive belt must be positioned over the disk hub and behind the drive belt idler (refer back to Diagram 7.16). Line up the drive belt in the center of the grooves on the disk hub. 15.
C762, C764, C764i Stairclimber 21. Push the disk assembly through the drive belt. Position the belt against the disk hub and behind the drive belt idler as you slide the disk assembly into the disk brackets. Important Make sure that the remote sensor assembly tabs straddle the disk target. 22. Using the 17mm open-end wrench, tighten the outer nuts on each end of the disk axle. 23. Return to Step 14. 24. Remove the set screws that secure the sheave to the sheave shaft.
C762, C764, C764i Stairclimber Procedure 7.21 - Replacing the Idler Spring or Drive Belt Idler Procedure 1. Remove the covers as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Loosen the drive belt by pushing down on the top of the drive belt idler arm. Hold the idler arm down while you pull the belt out of the sheave rim. Place the belt on the left end of the sheave shaft. 3.
C762, C764, C764i Stairclimber Diagram 7.19 - Idler Arm Assembly Spring Idler Arm Removing the Drive Belt Idler 10. Using the needle nose pliers, remove the hitch pin from the clevis pin that secures the idler arm to the climber frame. Hold the idler arm while you remove the clevis pin from the climber frame. Note: Set the idler arm assembly on a work bench while you perform the following steps. 11. Remove the retaining ring from the drive belt idler. 12.
C762, C764, C764i Stairclimber 14. Place the wave washer and drive belt idler onto the idler shaft weldment. 15. Install the retaining ring next to the drive belt idler. 16. Have an assistant position the idler arm assembly at its mounting position on the climber frame. Push the clevis pin through the climber frame and idler arm assembly. Push the hitch pin into the clevis pin. 17. Route the drive belt over the disk hub and behind the drive belt idler (refer back to Diagram 7.16). 18.
C762, C764, C764i Stairclimber 25. Check the operation of the climber as described in Section Four, then replace the covers as described in Procedure 7.1.
C762, C764, C764i Stairclimber Procedure 7.22 - Replacing a Stair Arm Assembly Removing the Stair Arm Assembly 1. Remove the covers as described in Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Press down the stairarm with one hand. With your other hand, grasp and pull the end of the toothed belt connected to the return spring. Release the stairarm.
C762, C764, C764i Stairclimber Note: Hold the belt clamp against the belt and slotted area on the underside of the pedal when you perform the next step. 12. Install the fasteners that secure the belt clamp to the pedal. 13. Lift the stair arm assembly from the frame weldment. Grasp the toothed belt and lift it over the toothed pulley. Route the belt under the idler pulley. 14. If you are replacing one stair arm assembly only... THEN... Continue with the next step. OTHERWISE...
C762, C764, C764i Stairclimber Procedure 7.23 - Replacing a Handlebar Assembly Removing the Handlebar Assembly 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Slide the handlebar boot up on the handlebar. 3.
C762, C764, C764i Stairclimber 6. If you are replacing only one handlebar assembly... THEN... Continue with the next step. OTHERWISE... Repeat Steps 2 through 5 for the second handlebar assembly; then continue with the next step. Replacing the Handlebar Assembly 7. Slide the handlebar boot onto the handlebar. Note: Be sure to mount the bell-shaped boot properly. The wide portion of the bell should be facing toward the base. 8. Slide the lower end of the handlebar assembly onto the handlebar post. 9.
C762, C764, C764i Stairclimber Procedure 7.24 - Replacing the Column Removing the Column 1. Turn off the climber with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Remove the handlebar assemblies as described in Procedure 7.24. 3. Remove the fasteners that secure the upper handlebar clamp to the column. 4.
C762, C764, C764i Stairclimber Note: It may be necessary to push the upper ribbon cable connector into the hole at the base of the column when you perform the next step. 7. Remove the display base plate and display housing assembly from the top of the column. The ribbon cable will be pulled out of the column as you lift the display base plate and display housing assembly. Note: When you perform the next step, make sure that the column mounting hardware does not fall into the climber. 8.
C762, C764, C764i Stairclimber Diagram 7.24 - Display Base Plate Display Base Plate Handlebar Clamp 11. Position the display base plate on top of the column. Line up the tabs on the back of the display base plate with the holes in the sides of the column. 12. Install the fasteners that secure the display base plate to the column.S 13. Slide the enclosure collar down the column and over the column mounting screws. Press down to ensure a snug fit. 14. Position the upper handlebar clamp next to the column.
C762, C764, C764i Stairclimber Wiring Diagram 8.
C762, C764, C764i Stairclimber Block Diagram 8.
C762, C764, C764i Stairclimber Wiring Diagram 8.
C762, C764, C764i Stairclimber Block Diagram 8.
