Precor C532i Service Manual
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Precor C532i Service Manual

Precor C532i Service Manual

Elliptical fitness crosstrainer
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C532i, C556i Navy Elliptical Fitness Crosstrainer
C532i, C536i, C556i Navy 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 Prod-
uct;
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, trou-
bleshooting 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.
© 2007 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20039-156
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  • Page 1 C532i, C536i, C556i Navy 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 Prod- uct; Call your dealer for service.

  • 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 C532i, C556i Navy, facing the display enclosure. Warning and Caution Statements and General Safety Guidelines Warning statements indicate a particularly dangerous activity.
  • Page 3 C532i, C556i Navy Elliptical Fitness Crosstrainer • 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 3...

  • Page 4: Required Tools And Equipment

    C532i, C556i Navy Elliptical Fitness Crosstrainer 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...

  • Page 5: Procedure 2.1 - Accessing The Hardware Validation Program

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 2.1 - Accessing the Hardware Validation Program The EFX diagnostic software cycles through the following tests: Hardware Validation Display Test Keyboard Test Heart Rate Brake Battery Procedure Note: Use the RESET key and the ten key keypad to enter the access code.
  • Page 6 “off”. Check all of the keys on the keyboard in this manner. Press and hold the CANCEL key (C532i) or BACK key (C556i Navy) for several seconds to proceed to the heart rate test.
  • Page 7 12. Press the CANCEL key (532i) or the BACK key (C56i Navy) to proceed to the brake test (C532i) or machine test (C556i Navy). 13. If you are testing a C556i Navy EFX skip to step 21, if you are testing a C532i continue with step 14.
  • Page 8 C532i, C556i Navy Elliptical Fitness Crosstrainer test or an key to proceed to a different test. 26. The A/D number (incline position number) will be displayed as A/D XX. Press the CANCEL key (532i) or the BACK key (C56i Navy) to proceed to the auto level test.

  • Page 9: Procedure 2.2 - Accessing The Information Display

    The display name “U-BASE SW” will be displayed, press the OK key, the U-Base software part number will be displayed. 10. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the Lower SW display. 11. The display name “LOWER SW” will be displayed, press the OK key, the lower software part number will be displayed.
  • Page 10 If the serial number is not present it can be uploaded per Procedure 2.5. 16. Press the CANCEL (C532i) or the BACK key (C556i Navy) key to proceed to the usage log display. 17. The display name “USAGE LOG” will be displayed, press the OK key.

  • Page 11: Procedure 2.3 - Accessing The Club Settings Display

    1 and 240 minutes or no time limit. 12. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the set max. pause time display. Page 11...
  • Page 12 1 and 120 seconds. 15. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the set cool down time display. 16. The display name “SET COOL DOWN TIME” will be displayed, press the OK key to proceed to the set cool down time display or an key to proceed to a different display.

  • Page 13: Procedure 2.4 - Documenting Software Problems

    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 13...

  • Page 14: Procedure 2.5 - Uploading Upper Pca Software And Serial Number Information

    This procedure is for Precor products manufactured with upper pca's that utilize flash memory rather than a firmware chip for software storage. Call Precor technical support at 800-347-4404 if you are usure of the type of software storage in the unit being serviced.
  • Page 15 Entering the serial number into the upper board of the Experience Line equipment, or other upper pca's, requires downloading and installing the latest version of the WinCSAFE software from the Precor Connection Website. Once the software is installed, follow these steps. Click on the WinCSAFE 2.0 icon to open the program.

  • Page 16: Section Three - Preventive Maintenance

    Regular Preventive Maintenance (Owner) Cleanliness of the EFX and its operating environment will keep maintenance problems and ser- vice calls to a minimum. Precor recommends that you perform the following preventive mainte- nance schedule. At the End of Each Day Wipe down the stairarms, ramps, wheels and frame with a damp cloth.
  • Page 17 C532i, C556i Navy Elliptical Fitness Crosstrainer Section Four - Checking EFX Operation This section provides you with a quick method of checking EFX operation. Check the operation of the EFX at the end of most maintenance procedures. Procedure Start striding on the EFX or plug the optional external power supply (when available) into the EFX and the AC outlet.

  • Page 18: Procedure 5.1 - Measuring The Resistance Of A Generator

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 5.1 - Measuring the Resistance of a Generator Caution If a external power supply is connected to the EFX, disconnect the external power supply from the EFX before continuing with this procedure. Procedure Remove the access cover, top cover, left and right side covers.
  • Page 19 C532i, C556i Navy Elliptical Fitness Crosstrainer Diagram 5.1 - Lower PCA Lower Interconnect Cable Battery Connection Load Resistor Generator Connections Connector Page 19...

  • Page 20: Procedure 5.2 - Inspecting And Adjusting Belt Tension

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 5.2 - Inspecting and Adjusting Belt Tension Procedure Remove the access cover, top cover, left and right side covers. See Procedure 7.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Sec- tion One, Things You Should Know.
  • Page 21 C532i, C556i Navy Elliptical Fitness Crosstrainer The belt gauge should read approximately 160 lbs. If the belt tension is significantly high or low the belt tension may be adjusted using the adjustment bolts shown in Diagram 5.2. To adjust the belt tension first straighten the locking tabs on both bolts. When adjusting the tension, turn both bolts equal amounts.

  • Page 22: Procedure 5.3 - Calibrating The Lift Motor

    C532i, C556i Navy Elliptical Fitness Crosstrainer 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. Remove the two bolts that retain the lift yoke to the ramp assembly. Support the lift motor and ramp assembly as you separate the lift yoke from the ramp assembly.

  • Page 23: Procedure 6.1 - Troubleshooting The Lower And Upper Data Cable

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 6.1 - Troubleshooting the Lower and Upper Data Cable Typical symptoms associated with a defective data cable are either an error 30 or no power to the upper PCA. This procedure requires that you have a known good upper data cable, lower data cable and mid-point connector.
  • Page 24 C532i, C556i Navy Elliptical Fitness Crosstrainer If the lower data cable corrects the problem, replace the cable per Procedure 7.4. If the lower data cable does not correct the problem, re-connect the original lower data cable to the lower PCA and mid-point connector and continue with step 10.

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

    C532i, C556i Navy Elliptical Fitness Crosstrainer 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 WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Sec- tion One.
  • Page 26 C532i, C556i Navy Elliptical Fitness Crosstrainer Set the display back in its mounting position and reconnect the data cable. If a “STUCK KEY” message is immediately displayed when the EFX is powered up, replace the upper PCA. If a “STUCK KEY” message is not displayed when the EFX is powered up, replace the display housing front panel.

  • Page 27: Procedure 6.3 - Upper Display Does Not Illuminate

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 6.3 - Upper Display does not Illuminate Because this is a self powered unit, the display will not illuminate until the EFX is used or the optional external power supply is equipped. If the optional external power supply is equipped, the display should be constantly illuminated.
  • Page 28 C532i, C556i Navy Elliptical Fitness Crosstrainer Diagram 6.4 - Partial View of Lower PCA DGND, TP4 PROM +5D, TP13 DS1 LED J2 Connector 10. Troubleshoot the upper to lower PCA interconnect cables per Procedure 6.1. 11. If the upper to lower interconnect cables are found to be good, replace the upper PCA.

  • Page 29: Procedure 6.4 - Troubleshooting The Generator

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 6.4 - Troubleshooting the Generator The generator performs three functions in the EFX. First, by controlling the amount of electrical load applied to the generator, the user’s pedalling resistance is controlled. Second, the generator is used to charge the EFX’s internal battery.

  • Page 30: Procedure 6.5 - Troubleshooting Hand Held Heart Rate

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 6.5 - Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system, that is, it can accept a heart rate signal from either the hand held heart rate contacts on the unit’s handlebar or from a Polar heart rate chest strap transmitter.
  • Page 31 C532i, C556i Navy Elliptical Fitness Crosstrainer receive a heart rate reading within ten seconds. If a hand held signal is not being accepted, access the diagnostic program (Procedure 2.1). Advance to the heart rate display portion of the diagnostic program. Verify that a hand held...
  • Page 32 C532i, C556i Navy Elliptical Fitness Crosstrainer Constant or intermittent readings when neither the hand held or chest strap is in use 11. Constant or intermittent heart rate readings when neither heart rate system is in use is caused by something in the near vicinity radiating RF energy that is being received by the chest strap portion of the heart rate PCA.

  • Page 33: Procedure 6.6 - Troubleshooting The Incline System

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 6.6 - Troubleshooting the Incline System The incline motor is a 12 Vdc motor with an internally driven 1 KΩ potentiometer used to track ramp position. Because the incline motor is a DC motor, incline motor direction is controlled by the polarity of the DC voltage applied to the incline motor.
  • Page 34 C532i, C556i Navy Elliptical Fitness Crosstrainer Remove both front covers. Enter the hardware validation program, if necessary, per Procedure 2.1. Connect a DC volt meter to the incline motor cable as follows: voltmeter common lead to terminal 2 (brown wire) and voltmeter “hot” lead to terminal 3 (red wire).

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

    C532i, C556i Navy Elliptical Fitness Crosstrainer 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 C532i, C556i Navy Elliptical Fitness Crosstrainer Diagram 7.2 - Rear Cover assembly with the Access Panel Removed Snap Mounting Screw Remove the two screws that fasten the wedge cover to the frame and remove the wedge cover. See Diagram 7.3.
  • Page 37 C532i, C556i Navy Elliptical Fitness Crosstrainer Diagram 7.4 - Bottom and Front Cover Sections Front Cover Section Bottom Cover Section Front View Rear View Remove the four screws that fasten the bottom cover section to the frame. Unsnap the front cover section from the bottom cover section and remove the front and bottom cover sections.

  • Page 38: Procedure 7.2 - Replacing A Display Front Panel, Upper Pca, Heart Rate Pca Or Metrics Pca

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.2 - Replacing a Display Front Panel, Upper PCA, Heart Rate PCA or Metrics PCA Procedure The keyboard is part of the display housing front panel. If the keyboard is not functioning properly, replace the display housing front panel.
  • Page 39 C532i, C556i Navy Elliptical Fitness Crosstrainer Removing and replacing the HR PCA 13. The HR PCA is located on the rear of the display, see Diagram 6.2. 14. Disconnect the HR input and output cables from the HR PCA. 15. Remove the HR PCA by carefully unsnapping it from its mounts on the display.

  • Page 40: Procedure 7.3 - Replacing A Lower Pca

    C532i, C556i Navy Elliptical Fitness Crosstrainer 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 41: Procedure 7.4 - Replacing A Lower Or Upper Data Cable

    C532i, C556i Navy Elliptical Fitness Crosstrainer 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 Proce- dure 6.1. The upper data cable is connected to the upper PCA at the rear of the display, and is then routed down the left outrigger tube.
  • Page 42 C532i, C556i Navy Elliptical Fitness Crosstrainer 12. Disconnect the data cable, from the frame, from the mid-point connector module. Disconnect the other end of the data cable from the lower PCA. 13. Tape the replacement lower data cable to the lower PCA end of the existing data cable.

  • Page 43: Procedure 7.5 - Replacing A Crankarm Assembly

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.5 - 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 44 C532i, C556i Navy Elliptical Fitness Crosstrainer 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 45: Procedure 7.6 - Replacing The Input Pulley Belt

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.6 - Replacing the Input Pulley Belt WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the access cover, top cover, left and right side rear covers per Procedure 7.1.

  • Page 46: Procedure 7.7 - Replacing The Generator Pulley Belt

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.7 - Replacing the Generator Pulley Belt WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.

  • Page 47: Procedure 7.8 - Replacing The Input Pulley Assembly

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.8 - Replacing the Input Pulley Assembly WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Sec- tion One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.
  • Page 48 C532i, C556i Navy Elliptical Fitness Crosstrainer Replace the crankarms per Procedure 7.5. The crankarms must be parallel to the frame uprights. Refer to Diagram 7.9. If necessary loosen the four drive unit mounting bolts, align the drive unit and torque the drive unit mounting bolts to 400 inch pounds.

  • Page 49: Procedure 7.9 - Replacing The Step-Up Pulley Assembly

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.9 - Replacing the Step-Up Pulley Assembly WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Sec- tion One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.

  • Page 50: Procedure 7.10 - Replacing A Generator

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.10 - Replacing a Generator WARNING When the unit is used, stairarms are in motion or the generator is rotated by any means, the generator will produce potentially hazardous voltages even when the battery is disconnected.
  • Page 51 C532i, C556i Navy Elliptical Fitness Crosstrainer Set the replacement generator at its mounting position. Remove the three generator mounting screws, the three bearing clamp screws and the bearing clamp. Lift the generator and place the drive belt around the generator’s pulley.

  • Page 52: Procedure 7.11 - Replacing A Battery

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.11 - Replacing a Battery Remove the access cover, top cover, left and right side covers per Procedure 7.1. Disconnect the red wire from the positive terminal of the battery and the black wire from the negative terminal of the battery.

  • Page 53: Procedure 7.12 - Replacing A Wheel Assembly

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.12 - 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 54 C532i, C556i Navy Elliptical Fitness Crosstrainer 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.

  • Page 55: Procedure 7.13 - Replacing A Stairarm Pedal

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.13 - 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 56: Procedure 7.14 - Replacing A Stairarm

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.14 - Replacing a Stairarm 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 57: Procedure 7.15 - Replacing A Ramp Assembly

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.15 - 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 58 C532i, C556i Navy Elliptical Fitness Crosstrainer Diagram 7.12 - Upper Ramp Mounting Upper Ramp Mounting Bolts Replace both stairarms per Procedure 7.11. Replace the left, right, top and access panel cover sections per Procedure 7.1. Page 58...

  • Page 59: Procedure 7.16 - Replacing A Moveable Handlebar

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.16 - Replacing a Moveable Handlebar Remove the bolt that fastens the forward end of the connecting link to the moveable handlebar. See Diagram 7.14 Diagram 7.14 - Moveable Handlebar, Lower End Connecting Link...
  • Page 60 C532i, C556i Navy Elliptical Fitness Crosstrainer Remove the outrigger tube per Procedure 7.18. Using a 1/2 inch wrench on the moveable handlebar’s axle, unscrew and remove the moveable handlebar. See Diagram 7.16. Diagram 7.16 - Moveable Handlebar Moveable Handlebar Axle Set the replacement moveable handlebar in its mounting position.

  • Page 61: Procedure 7.17 - Replacing A Front Cover Section

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing a Front Cover Section It is only necessary to perform as much of this procedure as is required to access the cover being replaced. Grasp the upper front cover section and lift upwards to remove it. See Diagram 7.17 Diagram 7.17 - Front Covers...
  • Page 62 C532i, C556i Navy Elliptical Fitness Crosstrainer The lower rear cover must be removed before the upper rear cover. Remove the two screws in the bottom of the lower rear cover. Slide the rear cover rearward and off of the EFX. See Diagram 7.19.

  • Page 63: Procedure 7.18 - Replacing An Outrigger Tube

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.18 - Replacing an Outrigger Tube Remove the display bracket cover from the rear of the display. Carefully, lift the front of the EFX and place it on a temporary support, such as a block of wood.
  • Page 64 C532i, C556i Navy Elliptical Fitness Crosstrainer If you are removing the right hand outrigger tube, skip to step 12. If you are removing the left hand outrigger tube, continue with step 7. Disconnect the data cable from the upper printed circuit board. If applicable. See Diagram 6.2.

  • Page 65: Procedure 7.19 - Replacing A Ramp Mounting Bracket

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.19 - 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 66: Procedure 7.20 - Replacing A Lift Motor

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.20 - Replacing a Lift Motor Remove the upper and lower front covers per Procedure 7.17. Remove the bolts that fasten the upper end of the ramp to the lift motor yoke. Carefully, draw the lift motor yoke out of the ramp and lay the ramp down against the frame.
  • Page 67 C532i, C556i Navy Elliptical Fitness Crosstrainer 11. Raise the ramp and slide the lift yoke into the ramp and fasten it with the hardware removed in step 3. 12. Replace the lower and upper front covers. 13. Thoroughly, test the EFX per Section Four.

  • Page 68: Procedure 7.21 - Replacing The Prom

    C532i, C556i Navy Elliptical Fitness Crosstrainer Procedure 7.21 - 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.
  • Page 69 C532i, C556i Navy Elliptical Fitness Crosstrainer Wiring Diagram 8.1 - C532i, C556i Navy EFX J3-2 J3-3 Incline Motor J3-4 J3-5 J3-6 Page 69...
  • Page 70 C532i, C556i Navy Elliptical Fitness Crosstrainer Block Diagram 8.2 - C532i, C556i Navy EFX Page 70...

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