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Precor C544 Service Manual

Precor C544 Service Manual

Elliptical fitness crosstrainer
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C544 Elliptical Fitness Crosstrainerl
C544 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.
© 2003 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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  • Page 1 C544 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

    C544 Elliptical Fitness Crosstrainer 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 544, facing the display enclosure.

  • 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/Dealer”. Page 3...

  • Page 4: Procedure 3.1 - Software Access Codes

    C544 Elliptical Fitness Crosstrainer Procedure 3.1 - Software Access Codes Over the years the codes used to access the various software diagnostics features have changed. Currently we are using a “standardized” set of access codes. These codes will be used on all current and future software.

  • Page 5: Procedure 3.2 - Accessing The Diagnostic Software

    C544 Elliptical Fitness Crosstrainerl Procedure 3.2 - Accessing the Diagnostic Software The EFX 544 diagnostic software cycles through the following tests: • Performing LED Diagnostics • Checking the Lift Calibration Number • Determining Software Version • Heart Rate Diagnostic •...
  • Page 6 C544 Elliptical Fitness Crosstrainer Diagram 3.1 - C544 Display Press ENTER, then release. Note the software version number displayed in the right middle display window. Note: If you cannot determine the software version number in this manner, look at the PROM (U3) mounted on the upper PCA.
  • Page 7 C544 Elliptical Fitness Crosstrainerl 12. If the left display window column illuminates appropriately as each key is pressed... THEN... OTHERWISE... The keypad test passed successfully; Replace the upper PCA as described continue with the next step. in Procedure 8.2. 13. End the keypad test by pressing the RAMP and RESISTANCE keys, simultaneously.

  • Page 8: Procedure 3.3 - Displaying The Odometer

    Procedure Plug the power cord into the wall outlet, then turn on the EFX 544 with the circuit breaker. With the PRECOR EFX 544 banner scrolling, press the RAMP and RESISTANCE keys, simultaneously or keys RESET,6,5, sequentially. The message EFX 544 ODOMETER will scroll across the left display window.

  • Page 9: Procedure 3.4 - Club Settings

    Procedure Plug the power cord into the wall outlet, then turn on the EFX 544 with the circuit breaker. With the PRECOR EFX 544 banner scrolling, press the RESISTANCE and QUICK START keys simultaneously or keys RESET,5,6,5,1,5,6,5, sequentially. Either U. S.

  • Page 10: Procedure 3.5 - Documenting Software Problems

    If you isolated 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. When a problem occurs, record the following information: •...
  • Page 11 C544 Elliptical Fitness Crosstrainerl Section Four - Checking EFX 544 Operation This section provides you with a quick method of checking EFX 544 operation. Check the operation of the EFX 544 at the end of most maintenance procedures. Procedure Plug the power cord into the wall outlet, then turn on the EFX 544 with the circuit breaker.

  • Page 12: Procedure 5.1 - Inspecting And Adjusting The Gap Between The Disk And Magnet Assembly

    C544 Elliptical Fitness Crosstrainer Procedure 5.1 - Inspecting and Adjusting the Gap Between the Disk and Magnet Assembly Note: This procedure is applicable only to units manufactured prior to March 20, 1997 Procedure Turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 13 C544 Elliptical Fitness Crosstrainerl Loosen the two screws that secure the magnet assembly to the magnet pivot assembly. IMPORTANT Do not loosen the screws too much. Although you must be able to move the magnet assembly along the adjustment slots, the assembly must stay in place after it is moved.

  • Page 14: Procedure 5.2 - Measuring The Resistance Of A Magnet

    C544 Elliptical Fitness Crosstrainer Procedure 5.2 - Measuring the Resistance of a Magnet Caution Remove power from the EFX 544 before you measure magnet resistance. Procedure Turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 15 C544 Elliptical Fitness Crosstrainerl Diagram 5.2 - Magnet Wiring Page 15...

  • Page 16: Procedure 5.3 - Calibrating The Lift Motor

    C544 Elliptical Fitness Crosstrainer Procedure 5.3 - Calibrating the Lift Motor Note: The lift motor must be removed for calibration. Removing the Lift Motor Assembly Set the ramp (lift) at level 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 17 C544 Elliptical Fitness Crosstrainerl Calibrating the Lift Motor Assembly 13. Position the lift motor assembly on the floor, close to the EFX 544 frame. Diagram 5.3 - Lift Motor Assembly Page 17...
  • Page 18 12 is shown on the display. 18. Exit the diagnostic program. 19. With the Precor banner scrolling, turn off the EFX 544 with the circuit breaker. Unplug the power cord from the wall outlet. 20. Without allowing the lead screw to turn, thread the lift tube clockwise until it reaches the top of the lead screw.
  • Page 19 C544 Elliptical Fitness Crosstrainerl Diagram 5.4 - Exploded View of the Lift System 28. Insert the upper lift shaft through the EFX 544 frame and upper lift motor assembly. Replace the plastic spacers (if you have a unit built after June 19, 1996) and the snap ring on the end of the upper lift shaft.

  • Page 20: Procedure 6.1 - Troubleshooting The Ribbon Cable

    C544 Elliptical Fitness Crosstrainer Procedure 6.1 - Troubleshooting the Ribbon Cable With the lift set at level 1, turn off the EFX 544 with the circuit breaker. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One.
  • Page 21 C544 Elliptical Fitness Crosstrainerl Diagram 6.1 - Upper Column Assembly 13. Position the upper display module on the upper frame member (see Diagram 6.1). Install the screws that secure the display module to the frame member. 14. Remove the ground lead of the wrist strap from the EFX 544 frame, then remove the wrist strap from your arm.

  • Page 22: Procedure 6.2 - Troubleshooting The Keypad And Upper Pca

    C544 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. This troubleshooting procedure gives you the information you need to determine which of these components is malfunctioning.
  • Page 23 C544 Elliptical Fitness Crosstrainerl Table 6.1 - Voltage Test Points (Function Keys Not Pressed) Place the positive lead of the The voltmeter should read... voltmeter on... Pin 3 of J3 5 Vdc ± 500 mVdc Pin 4 of J3 5 Vdc ± 500 mVdc Pin 5 of J3 5 Vdc ±...

  • Page 24: Procedure 6.3 - Troubleshooting The Speed Sensor

    C544 Elliptical Fitness Crosstrainer Procedure 6.3 - Troubleshooting the Speed Sensor Circuit Description The speed sensor is an infrared photoeye that straddles a target. The target is either a plastic disc with alternate clear and opaque sections or a plastic “fan” type device. The target rotates as the unit is operated and the infrared beam is interrupted when an opaque section or “fan blade”...

  • Page 25: Procedure 6.4 - Troubleshooting The Lift System (Electrical)

    If you have performed all of the above tests and the lift system is still not functioning, call Precor Technical Support. Set the C544 circuit breaker in the “off” position. Remove the F2 (2 amp slow blow) fuse from the lower PCA. Measure the fuse with an ohmmeter. The measurement should be 1Ω...
  • Page 26 C544 Elliptical Fitness Crosstrainer 10. Monitor terminals 1 and 3 (white and black wires) of P2. Enter the manual program and press the RAMP key. The measurement should be approximately 120 Vac (line voltage). If the voltage is present and the lift motor moves normally skip to step 12. The voltage will only be present until such time as an error occurs.

  • Page 27: Procedure 6.5 - Troubleshooting The Lift System (Mechanical)

    C544 Elliptical Fitness Crosstrainerl Procedure 6.5 - Troubleshooting the Lift System (mechanical) Potential Symptoms This procedure will cover two separate areas, a mechanically “frozen” lift system and a noisy lift symptom. A mechanically “frozen” lift system is a lift system in which the lift motor is powered but the lift does not move.
  • Page 28 Recalibrate the lift per Procedure 5.3. If the C544 is noisy when the stairarms are operated, skip to step 12. If the C544 is noisy when the lift motor is operated continue with step 10.

  • Page 29: Procedure 6.6 - Troubleshooting The Eddy Current System (Electrical)

    If the flywheels do no turn freely, continue with Procedure 6.7. If the C544 was manufactured prior to March 20, 1997, a magnet and eddy current disc with an adjustable gap was used. If appropriate, check the magnet gap per Procedure 5.1.
  • Page 30 They are lower PCA, ribbon cable and upper PCA. Replace only one part at a time. If the new part does not correct the problem replace the original part. 12. If you have performed all of the above tests and the resistances still incorrect, call Precor Technical Support.

  • Page 31: Procedure 6.7 - Troubleshooting The Eddy Current System (Mechanical)

    C544 Elliptical Fitness Crosstrainerl Procedure 6.7 - Troubleshooting the Eddy Current System (mechanical) Note: Over a period of time and usage, the lubrication of the main flywheel oilite bushings and the stairarm oliite bushings will loose effectiveness. This will cause the flywheels and/or stairarms to turn harder, thus increasing the force required to operate the unit.

  • Page 32: Procedure 7.1 - Replacing The Covers

    C544 Elliptical Fitness Crosstrainer Procedure 7.1 - Replacing the Covers Replacing the Front Cover Turn on the EFX 544 with the circuit breaker, then press QUICKSTART on the display panel. Press Ramp until the lift is set at level 1.
  • Page 33 C544 Elliptical Fitness Crosstrainerl Procedure 7.2 - Replacing the Display Enclosure or Upper PCA Note: Anti-static kits (part number 20024-101) can be ordered from Precor. Removing the Display Enclosure Turn off the EFX 544 with the circuit breaker. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 34 C544 Elliptical Fitness Crosstrainer 10. Line up the blank place on the end of the keypad ribbon cable with the blank pin position on the keypad connector. Place a full twist in the end of the keypad ribbon cable, then carefully connect it to the upper PCA.

  • Page 35: Procedure 7.3 - Replacing The Prom

    C544 Elliptical Fitness Crosstrainerl Procedure 7.3 - Replacing the PROM Anti-static kits (part number 20024-101) can be ordered from Precor. 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 36: Procedure 7.4 - Replacing The Lower Pca

    Remove the nuts that secure the lower PCA to the lower electronics bracket. Set aside the lower PCA for eventual shipment to Precor. Replacing the Lower PCA Remove the P1 connector from the lower PCA that has been removed from the EFX 544 and install it on the replacement lower PCA.

  • Page 37: Procedure 7.5 - Replacing The Ribbon Cable

    C544 Elliptical Fitness Crosstrainerl Procedure 7.5 - Replacing the Ribbon Cable Removing the Ribbon Cable With the lift set at level 1, turn off the EFX 544 with the circuit breaker. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 38 C544 Elliptical Fitness Crosstrainer 14. Re-install the front cover as described in Procedure 7.1, then check the operation of the EFX 544 as described in Section Four. Page 38...

  • Page 39: Procedure 7.6 - Replacing The Power Entry Module

    C544 Elliptical Fitness Crosstrainerl Procedure 7.6 - Replacing the Power Entry Module Removing the Power Entry Module With the lift set at level 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.

  • Page 40: Procedure 7.7 - Replacing The Circuit Breaker

    C544 Elliptical Fitness Crosstrainer Procedure 7.7 - Replacing the Circuit Breaker Removing the Circuit Breaker With the lift set at level 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.

  • Page 41: Procedure 7.8 - Replacing The Inductor

    C544 Elliptical Fitness Crosstrainerl Procedure 7.8 - Replacing the Inductor Removing the Inductor With the lift set at level 1, turn off the EFX 544 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.

  • Page 42: Procedure 7.9 - Replacing The Filter Capacitor

    C544 Elliptical Fitness Crosstrainer Procedure 7.9 - Replacing the Filter Capacitor Removing the Capacitor With the lift set at level 1, turn off the EFX 544 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.
  • Page 43 C544 Elliptical Fitness Crosstrainerl 10. Re-install the front cover as described in Procedure 7.1, then check the operation of the EFX 544 as described in Section Four. Diagram 7.3 - Capacitor Wiring Page 43...

  • Page 44: Procedure 7.10 - Replacing The Lift Motor Assembly

    C544 Elliptical Fitness Crosstrainer Procedure 7.10 - Replacing the Lift Motor Assembly Removing the Lift Motor Assembly With the lift set at 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 45 C544 Elliptical Fitness Crosstrainerl Replacing the Lift Motor Assembly 14. Inspect the upper and lower lift shafts. If they are worn, install new shafts on the EFX 544. 15. Position the lift motor assembly against the lift guide. Align the bore in the lift tube with the bore in the lift bracket.
  • Page 46 C544 Elliptical Fitness Crosstrainer 19. Insert the upper lift shaft through the EFX 544 frame and upper lift motor assembly. Replace the plastic spacers (if you have a unit built after June 19, 1996) and the snap ring on the end of the upper lift shaft.

  • Page 47: Procedure 7.11 - Replacing The Lift Guide

    IMPORTANT Units built before January 23, 1996, have a T-shaped lift guide. If you must replace an older style lift guide, order a lift guide replacement kit from Precor (kit part number:50530-103). Removing the Lift Guide With the lift set at level 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.

  • Page 48: Procedure 7.12 - Replacing The Lift Motor Capacitor

    C544 Elliptical Fitness Crosstrainer Procedure 7.12 - Replacing the Lift Motor Capacitor With the lift set at level 1, turn off the EFX 544 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.

  • Page 49: Procedure 7.13 - Replacing The Lift Axle Wear Tube

    C544 Elliptical Fitness Crosstrainerl Procedure 7.13 - Replacing the Lift Axle Wear Tube Removing the Lift Axle Wear Tube Turn off the EFX 544 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.
  • Page 50 C544 Elliptical Fitness Crosstrainer If you removed the lift axle wear tube because you are installing a new lower lift shaft (as described in Procedure 7.10), visually inspect the lift axle wear tube. If the wear tube is worn or defective . . .

  • Page 51: Procedure 7.14 - Replacing A Flywheel

    C544 Elliptical Fitness Crosstrainerl Procedure 7.14 - Replacing a Flywheel Removing a Flywheel Turn off the EFX 544 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.
  • Page 52 C544 Elliptical Fitness Crosstrainer Diagram 7.6 - EFX 544 Flywheel Replacing a Flywheel 10. Remove the tapered bushing from the flywheel hub. Inspect the bushing for wear or damage. If the bushing must be replaced, put a new bushing in the flywheel hub.
  • Page 53 C544 Elliptical Fitness Crosstrainerl 14. Place a 2 x 4 piece of lumber or a long-handled tool through the flywheel spoke and against the front of the rear frame upright. 15. Install the bolt and washer that secure the flywheel onto the EFX 544. Torque the bolt to 100 foot-pounds.

  • Page 54: Procedure 7.15 - Replacing The Flywheel Belt

    C544 Elliptical Fitness Crosstrainer Procedure 7.15 - Replacing the Flywheel Belt Removing the Flywheel Belt Turn off the EFX 544 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.

  • Page 55: Procedure 7.16 - Replacing The Tension Spring

    C544 Elliptical Fitness Crosstrainerl Procedure 7.16 - Replacing the Tension Spring Removing the Tension Spring Turn off the EFX 544 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.

  • Page 56: Procedure 7.17 - Replacing The Speed Sensor Assembly

    C544 Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing the Speed Sensor Assembly IMPORTANT On units built after August 21, 1996, the speed sensor cable is connected to the speed sensor via a connector. Removing the Speed Sensor Assembly With the lift set at level 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 57 C544 Elliptical Fitness Crosstrainerl 16. If the unit you are servicing was built before August 22, 1996 . . . THEN . . . OTHERWISE . . . Connect the speed sensor cable to Connect the speed sensor cable to the lower PCA.

  • Page 58: Procedure 7.18 - Replacing The Magnet Cable Assembly

    C544 Elliptical Fitness Crosstrainer Procedure 7.18 - Replacing the Magnet Cable Assembly Removing the Magnet Cable Assembly With the lift set at level 1, turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.

  • Page 59: Procedure 7.19 - Replacing The Magnet Pivot Assembly

    C544 Elliptical Fitness Crosstrainerl Procedure 7.19 - Replacing the Magnet Pivot Assembly IMPORTANT Use this procedure when you must install a new magnet assembly, eddy current disk, target label and magnet pivot assembly. Removing the Magnet Pivot Assembly Turn off the EFX 544 with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 60 C544 Elliptical Fitness Crosstrainer Diagram 7.7 - Magnet Pivot Assembly 12. Position the speed sensor so that the sensor "legs" evenly straddle the edge of the speed label. 13. Replace the screw(s) that secure(s) the speed sensor to the magnet pivot assembly.

  • Page 61: Procedure 7.20 - Replacing The Stair Arm Wheel

    544. Use wrenches to remove the wheels from the stair arm assembly. Replace with the new wheel assembly (Precor part number: 50532-108). Install the tapered aluminum spacer (shown in Diagram 7.8) to prevent noise during operation. Diagram 7.8 - Stairarm Wheel...
  • Page 62 C544 Elliptical Fitness Crosstrainer The wheel assembly consists of a wheel, axle, spacer, washer and locknut. Securely tighten the locknut. Rotate the stair arms towards the front of the EFX 544. Position the stair arms on the rail assembly. Re-install the rear cover as described in Procedure 7.1, then check the operation of the EFX 544 as described in Section Four.

  • Page 63: Procedure 7.21 - Replacing The Stair Arm Assembly

    C544 Elliptical Fitness Crosstrainerl Procedure 7.21 - Replacing the Stair Arm Assembly Removing the Stair Arm Assembly Turn off the EFX 544 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.
  • Page 64 C544 Elliptical Fitness Crosstrainer Diagram 7.9 - Stairarm Assembly Install the stair arm assembly on the flywheel and secure with the bolt and washer. Torque the bolt to 100 foot-pounds. 10. Rotate the stair arms towards the front of the EFX 544. Position the stair arms on the ramp assembly.

  • Page 65: Procedure 7.22 - Replacing A Handlebar

    C544 Elliptical Fitness Crosstrainerl Procedure 7.22 - Replacing a Handlebar Removing a Handlebar Loosen the four screws that hold the handlebars in the upper and lower handlebar clamps. Grasp and pull the ends of the handlebar away from the handlebar clamps.
  • Page 66 C544 Elliptical Fitness Crosstrainer Wiring Diagram 8.1 - C544 120 Vac Page 66...
  • Page 67 C544 Elliptical Fitness Crosstrainerl Block Diagram 8.2 - C544 120 Vac Page 67...
  • Page 68 C544 Elliptical Fitness Crosstrainer Wiring Diagram 8.3 - C544 240 Vac Page 68...
  • Page 69 C544 Elliptical Fitness Crosstrainerl Block Diagram 8.4 - C544 240 Vac Page 69...

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