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Precor 5.25 Service Manual

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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
20039-162
1

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Summary of Contents for Precor 5.25

  • Page 1 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.
  • Page 2 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 standing on the EFX 5.25 facing the display enclosure. Warning and Caution Statements and General Safety Guidelines Warning statements indicate a particularly dangerous activity.
  • Page 3 • 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. 20039-162...
  • Page 4 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 open-end wrench set Supplies blue loctite...
  • Page 5 Procedure 2.1 - Accessing the Service Mode The EFX service mode software cycles through the following tests: Upper and Lower Software Versions Key Test Factory Set 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.
  • Page 6 Diagram 2.1 - 5.25 Display 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.
  • Page 7 If do you do not wish to restore the factory settings use the keys to move to the display test or key test. 10. If you wish to restore the factory settings, press the ENTER key. Cleared will be momentarily displayed.
  • Page 8 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 and RESISTANCE keys, sequentially.
  • Page 9 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 10 Procedure 2.4 - Accessing the Production Check Mode This mode is used on the Precor production line to ensure that all of the display keys are functioning. Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch.
  • Page 11 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 12 If you isolated the problem to either the PROM, upper PCA, or lower PCA, include the information you have recorded with the malfunctioning PROM or PCA when you ship it to Precor. When a problem occurs, record the following information: •...
  • Page 13 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 14 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 15 Procedure 5.1 - Inspecting and Adjusting Belt 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 Diagram 5.2 - Measuring Belt Tension 15 lbs 1/4” Loosen, but do not remove the idler pulley mounting bolt. IF... THEN... The belt tensioning gauge reads Turn the 8mm hex cap, idler pulley tension bolt less than 14 pounds clockwise, in quarter-turn increments, until the belt tensioning gauge reads 14 - 16 pounds @1/4”...
  • Page 17 Procedure 5.2 - Drive Input Assembly Adjustments This procedure ensures that the drive input assembly is 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” 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 18 Diagram 5.4 - 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 5.3 are within 1/16 inch. Torque the three loose pillow block mounting bolts to 120 inch pounds (10 foot pounds).
  • Page 19 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 into the yoke and fasten it with the bolts removed in step 6. Place the top retaining bracket in its mounting position and fasten it with the screws removed in step 4. 14. Set the front portion of the front cover in its mounting position and fasten it with the screws removed in step 3.
  • Page 21 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. Set the on/off switch in the “off”...
  • Page 22 Procedure 6.2 - Troubleshooting the Keypad and Upper 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 23 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 24 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 25 Diagram 6.3 ± 5 Vdc Speed Sensor Wire Connector Rotate the step up pulley so that the speed sensor magnet is next to the reed switch. Using a DC voltmeter, measure the voltage between the two terminals in the speed senor connector on the lower PCA.
  • Page 26 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.
  • Page 27 Procedure 6.4 - Troubleshooting the Eddy Current Drum Brake System Note: If the control circuit does not see an output from the speed sensor, it removes power from the eddy current system. Therefore, when it is necessary to check the pedaling resistance or take voltage measurements in the eddy current system it will be necessary to slowly turn the flywheels to ensure that the power time out has not occurred.
  • Page 28 Pedal the EFX and press the RESESTANCE button. While pedaling and the resistance is changing on the display monitor the magnetic position motor cable wheel. The motor cable wheel should be moving clockwise when the resistance level is increasing on the display. Continue pedaling and press the RESESTANCE button.
  • Page 29 If the readings are still significantly low or high replace the lower PCA. Diagram 6.8 Orange Wire Test Point Magnetic Position Motor Potentiometer If you have performed all of the above tests and the resistances are still incorrect, call Precor Technical Support. 20039-162...
  • Page 30 Check the line cord for nicked or cut wiring. Replace the line cord if necessary. 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.
  • Page 31 30. Disconnect the lift position cable from the lower PCA. Set the on/off switch to the “On” position. If LED 2 turns on replace the lift motor. 32. If you have performed all of the above tests and are unable to resolve the problem, contact Precor customer support...
  • Page 32 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 33 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 34 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 35 Diagram 7.1 - Top Cover Section Mounting Bottom Cover Section Remove the A.C. power cord from the A.C. input module. 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. Remove the bottom cover section.
  • Page 36 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 37 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 38 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.
  • Page 39 Diagram 7.2 Blue Wire (AC Neutral) Brown Wire (AC Hot) Incline Motor Connector Incline Potentiometer Connector Speed Sensor Connecto Magnet position Cable Connector Data Cable Connector 20039-162...
  • 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 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. Tape one end of the replacement data cable to the display end of the existing upper data cable. Carefully pull the existing upper data cable out of the hole in the bottom end of the right outrigger, as you feed the replacement data cable into the upper end of the right outrigger.
  • Page 42 24. Remove the tape fastening the two data cables and discard the old data cable. 25. Connect the new data cable to the connector module and to the lower PCA. 26. Slide the right outrigger into its mounting position. 27. Hand start but do not tighten the four lower and three upper right out rigger mounting bolts removed in steps 17 and 18.
  • Page 43 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 Replace the wires removed in step 4. 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. 10. Replace the AC boot. Replace the left and right hand cover sections per Procedure 7.1. Insert the A.C.
  • Page 45 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.
  • Page 46 Position the crankarm on the input pulley shaft so the parallel key is aligned with the slot on the crankarm and the slot of the input pulley shaft. Thread and hand tighten the crankarm mounting bolt into the input crankarm. Torque the bolt to 300 inch pounds (25 foot pounds). Thread and tighten the lock nut securely.
  • Page 47 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 Diagram 7.6 - Pillow Block Bearings Mounting Bolt Stamping Pillow Block Bearing Replace the stairarms per Procedure 7.16. Check drive input adjustment per Procedure 5.2. 14. Replace the top, left and right cover sections per Procedure 7.1. 20039-162...
  • Page 49 Procedure 7.8 - Replacing a Magnetic Brake Position Motor. 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 Remove the 2 motor mounting screws and discard motor. See Diagram 7.7 Diagram 7.8 Wire Tie Strap Motor Cable Wire Harness Motor Cable Linkage Wire Harness Insert the cable end into the slot of the magnetic brake position motor wheel and then coil the cable counter clockwise around the wheel until the cable housing is parallel to the cable retainer of the magnetic brake motor.
  • Page 51 Diagram 7.10 Brake Motor Mounting Holes Slide brake motor up so mounting holes align to tension position cable. Reconnect the magnetic brake position motor wire harness and the Magnetic Brake Position Motor linkage wire harness. Use a new wire tie strap to secure the magnetic brake position wire harness to the frame. Replace the top, left and right cover sections per Procedure 7.1.
  • Page 52 Procedure 7.9 - Replacing a Magnetic Brake Motor Position Cable 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 53 Procedure 7.10 - Replacing a Magnetic Brake 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 54 Diagram 7.12 - Magnetic Brake Assembly Step Up Pulley Drive Belt Adjustment Slot Idler Pulley Mounting Bolt Idler Pulley Idler Pulley Tensioner Bolt Magnetic Brake Thread the magnetic brake assembly mounting bolts into the magnetic brake assembly. 10. Slide the input belt onto the replacement input drive assembly as you set the input magnetic brake assembly in it’s mounting position in the EFX.
  • Page 55 Procedure 7.11 - 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 56 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 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 58 black spacer is on the bottom of the pivot block as shown in Diagram 7.14. Install and hand tighten the stairarm pivot block mounting hardware. The mounting bolt head must be on the top of the stairarm as shown in Diagram 7.14. Torque the stairarm pivot block mounting bolt to 180 inch pounds (15 ft./lbs).
  • Page 59 Procedure 7.14 - 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.
  • Page 60 Replace the left and right cover sections per Procedure 7.1. 20039-162...
  • Page 61 Procedure 7.15 - 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.
  • Page 62 One, Things You Should Know. Remove the left or right cover sections, as required, as described in Procedure 7.1. 5.23 & 5.25 only. Remove the bolt that fasten the stairarm link to the stairarm. See Diagram 7.17. Diagram 7.17 - 5.23 Stairarm Link...
  • Page 63 The mounting bolt head must be on the top of the stairarm as shown in Diagram 7.14. Torque the stairarm pivot block mounting bolt to 15 ft./lbs. 5.23 & 5.25 only. Fasten the stairarm link to the stairarm with the bolt removed in step 3. See Diagram 7.17.
  • Page 64 Procedure 7.17 - 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.
  • Page 65 Place the replacement ramp on the ramp cover aligning the mounting screws with mounting tabs of the ramp cover. See Diagram 7.19 Fasten the screws loosened in step 16. Diagram 7.19 Bottom Side of Ramp Bottom side of Ramp Cover Slide the replacement ramp yoke onto the incline lift nut and hand tighten the two upper yoke mounting bolts removed in step 7.
  • Page 66 Procedure 7.18 - Replacing a Moveable Handlebar Note: This procedure is for the 5.23 & 5.25 only. 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 67 Diagram 7.21 - 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 68 Procedure 7.19 - Replacing an 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 69 3. Torque the idler pulley mounting bolt to 120 inch pounds (10 foot pounds). Verify the tension of the belts per Procedure 5.1. Replace the left andright, access panel cover sections per Procedure 7.1. 20039-162...
  • Page 70 Procedure 7.20 - 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 EFX is in a solid stable position and will not tip. 5.23 &5.25 only. Remove the moveable handlebar per Procedure 7.18. If you are removing the right outrigger, care must be taken because the upper data cable is inside of the right outrigger.
  • Page 72 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. 10. Remove the data cable from the outrigger. 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 10 to the wire and carefully draw the data cable into the outrigger until the data cable appears at the other end.
  • Page 73 Procedure 7.22 - 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 and then pry the fuse module out of the power entry module.
  • Page 74 Procedure 7.23 - 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 75 10. Calibrate the lift motor per Procedure 5.3. Set the rear incline cover section in its mounting position. Move the lift motor into place with the lift nut in between the tines of the yoke. Fasten the lift nut to the yoke with yoke mounting bolts removed in step 5.
  • Page 76 Wiring Diagram 8.1 - 5.25 EFX 20039-162...

  • Page 77: Block Diagram

    Block Diagram 8.2 - 5.25 20039-162...