Precor 5.25 Service Manual
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Precor 5.25 Service Manual

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5.23, 5.25 Elliptical Fitness Crosstrainer
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.
© 2008 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20039-158

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  • Page 1 5.23, 5.25 Elliptical Fitness Crosstrainer 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.

  • Page 2: Section One - Things You Should Know

    To remove power from the EFX, the power cord must be disconnected from the wall outlet. Always ensure that the EFX is unplugged from the wall outlet when you inspect or adjust the EFX, or when you isolate, remove, or replace a 5.23, 5.25 EFX component. •...

  • Page 3: General Information

    • Do not use accessory attachments that are not recommended by the manufacturer-such attachments might cause injuries. General Information For the latest exploded view, part number and part pricing information, visit the Precor dealer website at “www.precor.com/connection.

  • Page 4: Required Tools And Equipment

    Required Tools and Equipment The following list is a summary of the tools and equipment required when you service Precor’s EFX. TOOLS EQUIPMENT phillips and flat-head screwdrivers digital multimeter standard and metric allen wrench sets Supplies open-end wrench set blue loctite...
  • Page 5 Display Test Procedure Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch. While pressing and holding the ENTER key, press the RESET, QUICK START and RESISTANCE keys, sequentially. Diagram 2.1 - 5.25 Display...
  • Page 6 SERVICE MODE PRESS ENTER will scroll across the display. keys move the selection between the Key Test, Factory Set and the Display Test. Key Test When Key Test is displayed, press the ENTER key to enter the key test mode. Press each key on the display, the key name will be displayed when the key is functioning correctly.
  • Page 7 Procedure 2.2 - Accessing the Odometer & Software Versions Procedure Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch. While pressing and holding the ENTER key, press the RESET. INCLINE RESISTANCE keys, sequentially. The upper display screen will scroll the upper and lower software versions.
  • Page 8 Procedure 2.3 - Accessing the Unit Change Mode Selecting United States standard units causes information to be displayed in miles. Information is displayed in kilometers if metric units are selected. After you select a measurement standard, the software accumulates and records workout information in the units of the measurement standard selected.
  • Page 9 See Procedure 5.3 for incline calibration details. The production mode also provides a means of testing all of the display keys. This mode is used on the Precor production line to set the incline calibration and to ensure that all of the display keys are functioning.
  • Page 10 Procedure 2.5 - Accessing the Error Log Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch. Press and hold the RESET key for four seconds. ERROR LOG will scroll across the upper display. If no errors are present in the error log, NO ERROR will scroll across the lower display.
  • Page 11 The action taken by the user just before the problem occurred. Problem-related information (such as how far into the program the problem occurred, the work level being used when the problem occurred, etc.). • The frequency of occurrence. • Contact precor technical support at 800-347-4404 to receive a return tag.

  • Page 12: Section Three - Preventive Maintenance

    Regular Preventive Maintenance (Owner) Cleanliness of the EFX and its operating environment will keep maintenance problems and service calls to a minimum. Precor recommends that you perform the following preventive maintenance schedule. At the End of Each Day Wipe down the stairarms, ramps, wheels and frame with a damp cloth.
  • Page 13 Procedure Plug the power cord into the wall outlet and set the on/off switch in the “on” position. With the PRECOR EFX banner displayed, press QUICK START. Select Resistance Level 1. Operate the EFX for 4–5 minutes. As you operate the EFX, concentrate on the operating sounds made by the unit.

  • Page 14: Procedure 5.1 - Measuring The Resistance Of An Eddy Current Magnet

    Procedure 5.1 - Measuring the Resistance of an Eddy Current Magnet Caution Remove power from the EFX before you measure magnet resistance. Procedure Set the on/off switch in the “off” position, 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.

  • Page 15: Procedure 5.2 - Inspecting And Adjusting Belt Alignment And Tension

    Procedure 5.2 - Inspecting and Adjusting Belt Alignment and Tension Procedure Set the on/off switch in the “off” position, remove the A.C. line cord from the A.C. outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 16 12. Belt tension must now be checked and if necessary corrected. Remember, if it is necessary to change belt tension, the belt alignment must be maintained. Diagram 5.3 - Drive Unit Input Belt Adjustment Slot Step Up Belt Input Belt Tension Bolt Input Belt Tensioner...
  • Page 17 Diagram 5.4 - Measuring Belt Tension 15 lbs 1/4” 15. If the locking tabs on the right and left step up belt tension bolts have not been straightened, use pliers to bend the locking tabs out of the way so that the bolts can be turned. IF...
  • Page 18 21. Slide a stout screwdriver blade into the adjustment slot, See Diagram 5.3, to the upper left of the idler pulley. Using the screwdriver as a lever, press the pulley down and to the right. While maintaining constant pressure on pulley, check the belt tension with your finger. When the belt tension feels correct, tighten and torque the input belt tension bolt to 200 inch pounds (17 foot pounds).

  • Page 19: Procedure 5.3 - Calibrating The Lift Motor

    Procedure 5.3 - Calibrating the Lift Motor In order to calibrate the lift motor, it is necessary to disconnect the lift motor from the ramp assembly. Set the on/off switch in the “off” position, remove the A.C. line cord from the A.C. outlet. Remove the six screws from the rear of the front cover.
  • Page 20 12. Turning the lift nut as little as possible (only enough to allow it to align in the yoke) slide the lift nut into the yoke and fasten it with the bolts removed in step 6. 13. Place the top retaining bracket in its mounting position and fasten it with the screws removed in step 4.

  • Page 21: Procedure 5.4 - Drive Input Assembly Adjustments

    Procedure 5.4 - Drive Input Assembly Adjustments This procedure ensures that the drive input assembly, the drive belts and the eddy current magnet are correctly adjusted and aligned. All of the checks described in this procedure must be performed to ensure proper operation. Set the on/off switch in the “off”...
  • Page 22 Diagram 5.7 - Pillow block Mounting Bolts Tap Here Loosen Loosen Loosen Do not Loosen Using a rubber mallet, gently tap the top of the pillow block with two loosened bolt (the right hand pillow block in our illustration) until the two measurements in Diagram 5.6 are within 1/16 inch.
  • Page 23 10. If the difference between the two measurements are greater than 1/16 inch, continue with step 11. If the difference is less than 1/16 inch, skip to “eddy current magnet adjustment”. 11. You will be adjusting one half of the difference between the two measurements with each of the step up pulley adjustment nuts.

  • Page 24: Procedure 6.1 - Troubleshooting The Lower And Upper Data Cable

    Procedure 6.1 - Troubleshooting the Lower and Upper Data Cable Typical symptoms associated with a defective data cable are either an unresponsive display or no power to the display. This procedure requires that you have a known good data cable, and mid-point connector.

  • Page 25: Procedure 6.2 - Troubleshooting The Keypad And Upper Pca

    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. Procedure Set the on/off switch in the “off” position. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One.
  • Page 26 The display housing front panel is equipped with the keypad. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service. 10. Access the service mode program per Procedure 2.1.

  • Page 27: Procedure 6.3 - Troubleshooting The Speed Sensor

    Procedure 6.3 - Troubleshooting the Speed Sensor Circuit Description The speed sensor is a reed switch. A magnet is mounted on the step up pulley. The magnet passes the speed sensor once per revolution. The output from the speed sensor is a 5 Vdc square wave, the frequency of which indicates the operating speed.
  • Page 28 PCA. Replace only one part at a time. If the new part does not correct the problem, replace the original part. If you have performed all of the above tests and the speed sensor is still not functioning, call Precor Technical Support. Check the operation of the EFX as described in Section Four.

  • Page 29: Procedure 6.4 - Troubleshooting The Eddy Current System

    They are lower PCA and upper PCA. Replace only one part at a time. If the new part does not correct the problem re-install the original part. If you have performed all of the above tests and there is still no resistance, call Precor Technical Support.
  • Page 30 (∞). If the resistance is significantly low, disconnect the J2 connector from the lower PCA and the eddy current magnet. 11. If you have performed all of the above tests and the resistances are still incorrect, call Precor Technical Support.

  • Page 31: Procedure 6.5 - Upper Display Does Not Illuminate

    If the reading in step 5 is significantly low, replace the lower PCA 10. If you have performed all of the above tests and are unable to resolve the problem, contact Precor customer support. 11. Plug the line cord into the wall outlet and set the on/off switch in the “on” position.
  • Page 32 17. If you have performed all of the above tests and are unable to resolve the problem, contact Precor customer support. Diagram 6.3 - Lower PCA J6 (Data Cable) J7 (Speed Sensor) TP26 (+7.5V) J5 (Lift Position) J4 (Lift Drive)

  • Page 33: Procedure 6.6 - Troubleshooting The Lift System

    Procedure 6.6 - Troubleshooting the Lift System Note: The lift motor is disabled when the EFX is not being used. The speed sensor must detect motion in order for lift operation to be enabled. In the following procedures, when lift motor movement is being tested the stairarms must be in motion.
  • Page 34 Replace only one part at a time. If the new part does not correct the problem, replace the original part If you have performed all of the above tests and the lift system is still not functioning, call Precor Technical Support.

  • Page 35: Procedure 7.1 - Replacing Or Removing A Rear Cover Section

    Procedure 7.1 - Replacing or Removing a Rear Cover Section Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 36 Diagram 7.1 - Top Cover Section Mounting Bottom Cover Section 12. Remove the A.C. power cord from the A.C. input module. 13. Remove the two screws that fasten the input module to the bottom cover section. 14. Remove four screws, two front and two rear, that fasten the bottom cover to the frame. 15.
  • Page 37 Top Cover Section 23. Set the top cover section in its mounting position and snap it into the front cover section. 24. Fasten the inside center portion and the rear outside portion of the top cover with the screws removed in step 7. Left Cover Section 25.
  • Page 38 Procedure 7.2 - Replacing a Display Front Panel or Upper PCA The keyboard is part of the display housing front panel. If the keyboard is not functioning properly, replace the display housing front panel. Removing the Display Housing Front Panel Set the on/off switch in the “off”...

  • Page 39: Procedure 7.3 - Replacing A Lower Pca

    Procedure 7.3 - Replacing a Lower PCA Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “off”...
  • Page 40 Procedure 7.4 - Replacing a Lower or Upper Data Cable Procedure Note: Before you install a new data cable, ensure that the data cable is defective. Refer to Procedure 6.1. The upper data cable is connected to the upper PCA at the rear of the display, and is then routed down the right outrigger tube.
  • Page 41 Remove the four bolts, two front and two rear, that fasten the lower portions of the right outrigger to the frame. Carefully slide the right outrigger away from the frame to expose the data cables and connector module at the bottom front portion of the right outrigger. Disconnect the upper data cable from the connector module.
  • Page 42 23. Remove the left hand rear cover section per Procedure 7.1. 24. Disconnect the data cable from the lower PCA. 25. Tape the replacement lower data cable to the lower PCA end of the existing lower data cable. Carefully pull the existing lower data cable out of the hole in the frame, near the front of the right outrigger, as you feed the replacement data cable into the frame.

  • Page 43: Procedure 7.5 - Replacing A Power Entry Module

    Procedure 7.5 - Replacing a Power Entry Module Procedure Note: The power entry module on this EFX is a multifunction unit. It functions as a power entry module, A.C. line fuse holder, on/off switch and A.C.line filter. Set the on/off switch in the off position. Remove the A.C. line cord from the A.C. outlet and from the power entry module.
  • Page 44 Set the replacement power entry module at it’s mounting position, secure the power entry module with the screws removed in step 4, torque the screws to 6-9 inch pounds. Replace the wires removed in step 3. Connect the blue wire to terminal D, the brown wire to terminal A and the green wire to the ground terminal of the power entry module.

  • Page 45: Procedure 7.6 - Replacing A Crankarm Assembly

    Procedure 7.6 - Replacing a Crankarm Assembly Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “off”...
  • Page 46 Clean the crankarm mounting bolt threads and the input pulley shaft threads with an alcohol swab. Allow them to dry and apply blue loctite to the crankarm mounting bolt threads. Position the crankarm on the input pulley shaft. Thread and hand tighten the crankarm mounting bolt into the input pulley shaft.

  • Page 47: Procedure 7.7 - Replacing A Pillow Block Bearing

    Procedure 7.7 - Replacing a Pillow Block Bearing Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 48 12. Replace the crankarm(s) per Procedure 7.6. Diagram 7.5 - Pillow Block Bearings Mounting Bolt Stamping Pillow Block Bearing 13. Replace the stairarms per Procedure 7.17. 14. Check drive input adjustment per Procedure 5.4. 15. Replace the top, left and right cover sections per Procedure 7.1.

  • Page 49: Procedure 7.8 - Replacing An Input Drive Assembly

    Procedure 7.8 - Replacing an Input Drive Assembly Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 50 Slide the step up and input belts onto the replacement input drive assembly as you set the input drive assembly in it’s mounting position in the EFX. Thread and hand tighten the pillow block mounting bolts into the drive weldment upright. Torque the pillow block mounting bolts to 120 inch pounds (10 foot pounds) starting with the bottom left hand bolt, then the bottom right hand bolt, the upper right hand bolt and then the upper left hand bolt.

  • Page 51: Procedure 7.9 - Replacing An Input Pulley Belt

    Procedure 7.9 - Replacing an Input Pulley Belt Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 52 Remove the input pulley belt and place the replacement input pulley belt in it’s place on the step up pulley assembly. 10. Set the step up pulley assembly with the step up and input belt at its mounting position in the drive unit.

  • Page 53: Procedure 7.10 - Replacing A Step-Up Pulley Belt

    Procedure 7.10 - Replacing a Step-Up Pulley Belt Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 54 14. Tighten the right and left hand step up belt tension bolts and the idler pulley mounting bolt to the settings marked in step 5. 15. Verify the tension of the belts per Procedure 5.2. 16. Replace the crankarm(s) per Procedure 7.6 17.

  • Page 55: Procedure 7.11 - Replacing A Step-Up Pulley Assembly

    Procedure 7.11 - Replacing a Step-Up Pulley Assembly Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.

  • Page 56: Procedure 7.12 - Replacing A Speed Sensor Assembly

    Procedure 7.12 - Replacing a Speed Sensor Assembly Procedure Set the on/off switch in the “off” position, 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.
  • Page 57 Procedure 7.13 - Replacing an Eddy Current Assembly Procedure Set the on/off switch in the “off” position, 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.

  • Page 58: Procedure 7.14 - Replacing A Stairarm Pivot Block

    Procedure 7.14 - Replacing a Stairarm Pivot Block Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 59 Slide the stairarm pivot block onto the crankarm pin and replace the wave washer, flat washer and retaining ring removed in step 6. Slide the stairarm onto the stairarm pivot block. Ensure that the red spacer is on the top and the black spacer is on the bottom of the pivot block as shown in Diagram 7.9.

  • Page 60: Procedure 7.15 - Replacing A Wheel Assembly

    Procedure 7.15 - Replacing a Wheel Assembly Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “off”...
  • Page 61 Roll the stairarm into the ramp channel from the rear of the ramp. Slide the stairarm pivot block onto the crankarm pin and replace the wave washer, flat washer and retaining ring removed in step 3. Replace the left and right cover sections per Procedure 7.1.

  • Page 62: Procedure 7.16 - Replacing A Stairarm Pedal

    Procedure 7.16 - Replacing a Stairarm Pedal Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “off”...

  • Page 63: Procedure 7.17 - Replacing A Stairarm

    Section One, Things You Should Know. Remove the left or right cover sections, as required, as described in Procedure 7.1. 5.25 only. Remove the bolt that fasten the stairarm link to the stairarm. See Diagram 7.12. Diagram 7.12 - 5.25 Stairarm Link...
  • Page 64 Diagram 7.9. Torque the stairarm pivot block mounting bolt to 15 ft./lbs. 11. 5.25 only. Fasten the stairarm link to the stairarm with the bolt removed in step 3. See Diagram 7.12.

  • Page 65: Procedure 7.18 - Replacing A Ramp Assembly

    Procedure 7.18 - Replacing a Ramp Assembly Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “on”...
  • Page 66 Slide the replacement ramp onto the lift motor yoke and hand. Hand start the two lower ramp mounting bolts removed in step 5. Fasten the upper end of the ramp to the lift motor yoke with the hardware removed in step 6. Torque the two lower ramp bolts to 480 inch pounds (40 foot pounds).

  • Page 67: Procedure 7.19 - Replacing A Moveable Handlebar

    Procedure 7.19 - Replacing a Moveable Handlebar Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “off”...
  • Page 68 Diagram 7.16 - Moveable Handlebar Cover Mounting Bolt Set the replacement moveable handlebar in its mounting position. Carefully hand start the moveable handlebar’s mounting bolt to avoid cross threading and then tighten. Set the connecting link in its mounting at the lower end of the moveable handlebar and fasten it with the hardware removed in step 2.

  • Page 69: Procedure 7.20 - Replacing A Idler Pulley

    Procedure 7.20 - Replacing a Idler Pulley Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed. Procedure Set the on/off switch in the “off”...

  • Page 70: Procedure 7.21 - Replacing A Front Cover Section

    Procedure 7.21 - Replacing a Front Cover Section Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. It is only necessary to perform as much of this procedure as is required to access the cover being replaced.

  • Page 71: Procedure 7.22 - Replacing An Outrigger Tube

    EFX is in a solid stable position and will not tip. 5.25 only. Remove the moveable handlebar per Procedure 7.19. If you are removing the right outrigger, care must be taken because the upper data cable is inside of the right outrigger.
  • Page 72 10. Carefully slide the outrigger away from the frame to expose the data cables and connector module at the bottom front portion of the right outrigger. 11. Remove the data cable from the outrigger. 12. Feed a wire into the replacement outrigger until it comes out of the opening at the other end. Tape the data cable, removed in step 11 to the wire and carefully draw the data cable into the outrigger until the data cable appears at the other end.

  • Page 73: Procedure 7.23 - Replacing A Ramp Mounting Bracket

    Procedure 7.23 - Replacing a Ramp Mounting Bracket Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.

  • Page 74: Procedure 7.24 - Replacing A Power Entry Module Fuse

    Procedure 7.24 - Replacing a Power Entry Module Fuse Procedure Set the on/off switch in the off position. Remove the A.C. line cord from the A.C. outlet and from the power entry module. Using a thin bladed screwdriver, carefully pry the fuse access door open. Using a thin bladed screwdriver, carefully pry the fuse module out of the power entry module.
  • Page 75 Procedure 7.25 - Replacing a Lift Motor Set the on/off switch in the “off” position. Remove the A.C. line cord from the A.C. outlet. Remove eight screws from the rear of the incline cover. Remove the two screws in the rear bottom portion of the incline cover.
  • Page 76 Remove the tubular metal insert from the lift motor mount and retain for later use. Remove the lift motor. 10. Set the replacement lift motor in its mounting position and slide the tubular metal insert removed in step 9 into the lift motor mount. Fasten the lift motor with the bolt removed in step 7.
  • Page 77 Procedure 7.26 - 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. The prom is a forty-four pin square package (PLCC44).
  • Page 78 Wiring Diagram 8.1 - 5.23, 5.25 EFX Mid-Point Connector Mid-Point Connector J4-1 AC Hot J4-2 J4-3 J5-1 AC Neutral J5-3 J5-4 J7-2 J1-2 J1-1 J7-6...
  • Page 79 Block Diagram 8.2 - 5.23, 5.25...

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