Precor C532i User manual

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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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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. Warning statements you will find in
this manual include:
• Removing the covers exposes high voltage components and potentially dangerous
machinery. Exercise extreme caution when you perform maintenance procedures with the
hood removed.
• During service operations you will be very close to moving machinery and high voltage
components. When you perform maintenance procedures with the covers removed, remove
jewelry (especially from ears and neck), tie up long hair, remove neck ties, and do not wear
loose clothing.
• Exercise caution when touching any wire or electrical component during EFX operation.
Caution statements are intended to prevent damage to the EFX as a result of the current activity.
Caution statements included in this manual are listed below:
• Notice the orientation notch on the lower PCA PROM. These components must be
positioned with the same notch orientation.
Safety guidelines you should know and follow include:
• Read the owner’s manual and follow all operating instructions.
• Visually check the EFX before beginning service or maintenance operations. If it is not
completely assembled or is damaged in any way, exercise extreme caution while operating
and checking the EFX.
• When operating the EFX, do not wear loose clothing. Do not wear shoes with heels or
leather soles. Check the soles of your shoes and remove any embedded stones. Tie long
hair back.
• Do not rock the unit. Do not stand or climb on the handlebars, display enclosure, or cover.
• Do not set anything on the handlebars, display enclosure, or cover. Never place liquids on
any part of the EFX other than a water bottle in the water bottle holder during normal
operation.
• To prevent electrical shock, keep all electrical components away from water and other
liquids.

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• 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”.

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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
drive ratchet and ratchet set
socket drive allen set cable ties
chip puller Spares
rubber mallet data cables
snap ring pliers
100 ft./lb. torque wrench
300 in./lb. torque wrench
automotive belt tension gauge

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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
RPM
Battery
Procedure
Note:
Use the RESET key and the ten key keypad to enter the access code.
1. Access the diagnostic program by pressing, keys RESET,5,1,7,6,5,7,6,1, sequentially.
Diagram 2.1 - C532i Display
Arrow Keys
OK Key
Cancel Key

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Diagram 2.2 - C556i Navy Display
2. The test name HARDWARE VALIDATION will scroll once across the display.
3. The test name “DISPLAY” will be displayed. Press the OK key to enter the display test or an
, key to proceed to a different test.
4. Each time you press the OK key a different block of LED’s will illuminate. Check each LED
in each block to ensure that all are functioning. As you move through the LED blocks, one
press of the OK key will cause all of the LED’s to be off.
5. Press the CANCEL key (532i) or the BACK key (C56i Navy) to proceed to the keyboard
test.
6. The test name “KEYBOARD” will be displayed. Press the OK key to enter the keyboard test
or an , key to proceed to a different test.
7. A graphical representation of all the keys on the keyboard will be displayed. When a key is
pressed the representation of the key on the display will be turned “off”. Check all of the
keys on the keyboard in this manner.
8. Press and hold the CANCEL key (C532i) or BACK key (C556i Navy) for several seconds to
proceed to the heart rate test.
556I
Arrow Keys
Back Key OK Key

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9. The test name “HEART RATE” will be displayed. Press the OK key to enter the heart rate
test or an , key to proceed to a different test.
10. Both the hand held heart rate and wireless heart rate function must be tested. A chest strap
heart rate transmitter or a heart rate test transmitter must be used to test the wireless heart
rate function.
11. When a heart rate signal is received, the unfiltered and filtered heart rates will be displayed.
In addition the Polar heart rate will be displayed in the “Heart Rate” window. The red heart
and the smart rate LED’s will illuminate.
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.
14. The test name “BRAKE” will be displayed. Press the OK key to enter the brake test or an ,
key to proceed to a different test.
15. Powerbits will be displayed in the upper window and the resistance level will be displayed in
the lower middle window. Pressing the resistance , keys will change the number of
power bits being applied to the eddy current system., ranging from 60 to 170 powerbits.
Because this is a self powered EFX, you must pedal fast enough to keep the EFX powered
up and the resistance up, otherwise the powerbits will bo below the selected setting.
16. Press the CANCEL key to proceed to the RPM test.
17. The test name “RPM” will be displayed. Press the OK key to enter the RPM test or an , 
key to proceed to a different test.
18. The current RPM will be shown as “PULSE XX”. The pulses are updated in real time and
will display the actual pulse count.
19. Press the CANCEL key to proceed to the battery test.
20. Skip to step 25.
21. The test name “MACHINE TEST” will be displayed. Press the OK key to enter the brake
test or an , key to proceed to a different test.
22. The test name “BRAKE” test will be displayed.
23. The powerbits will be displayed as PWRB XX. Press the BACK key to proceed to the RPM
test.
24. The revolutions per minute will be displayed as RPM XX. Press the BACK key to proceed to
the CROSSRAMP test.
25. The test name “CROSSRAMP” will be displayed. Press the OK key to enter the crossramp

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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.
27. The test name “AUTO LEVEL” will be displayed. Press the OK key to enter the auto level
test or an , key to proceed to a different test.
28. The auto level incline position will be displayed, press an , key to change the auto level.
29. Press the CANCEL key (532i) or the BACK key (C56i Navy) to proceed to the battery test.
30. The test name “BATTERY” will be displayed. Press the OK key to enter the battery test or
an , key to proceed to a different test.
31. The battery voltage will be displayed as “XX.X VDC”.
32. Press the CANCEL key to return to the Display test or the RESET key to exit.
33. You may press the RESET key at anytime in the hardware validation program to exit the
hardware validation program.

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Procedure 2.2 - Accessing the Information Display
Procedure
1. With the PRECOR EFX banner displayed, press keys RESET,6,5, sequentially.
Diagnostics Test
Odometer
Hour meter
U-Boot Software version
U-Base Software version
Lower software version
Metrics Board SW Part Number (C532i only)
Serial Number
Usage Log
Error log
2. The test name “DIAGS - INFORMATION DISPLAY” will scroll once across the display.
Press the OK key to proceed to odometer or use the , keys to proceed a different
display.
3. The display name “ODOMETER” will be displayed, press the OK key, the odometer value
will be displayed, as total strides accumulated.
4. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the hour meter
display.
5. The display name “HOUR METER” will be displayed, press the OK key, the hour meter will
be displayed, as the total number of hours of use. Fractional parts of an hour are stored
internally, the display will be truncated to the nearest full hour.
6. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the U-Boot SW
display.
7. The display name “U-BOOT SW” will be displayed, press the OK key, the U-Boot software
part number will be displayed.
8. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the U-Base SW
display
9. 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.

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12. Press the CANCEL (C532i) key to proceed to the Metrics board SW display or the BACK
key (C556i Navy) to proceed to the serial number display, skip to step.16.
13. The display name “METRICS BOARD SW PART NUMBER will be displayed, press the OK
key, the metrics board software part number will be displayed.
14. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the serial number
display.
15. The display name “SERIAL NUMBER” will be displayed, press the OK key, the serial
number will be displayed. 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.
18. The program used and the time the program was used will be displayed.
19. The keys , will scroll you through the list of programs that have been used.
20. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the error log
display.
21. The display name “ERROR LOG” will be displayed, press the OK key.
22. The first error log entry will be displayed “1: ERXX XX STRIDES XX HRS”.
23. Pressing the , keys will move you through the log entries. Press the OK key to view the
selected error. Entry 1 will be the most recent error log entry, with each succeeding entry
being older than the preceding entry.
24. If the error log is empty “NO ERRORS” will be displayed.
25. Pressing and holding the QUICK START key for 2 seconds will cause the prompt CLEAR?
to be displayed, holding the QUICK START for an additional 2 seconds will clear all existing
entries from the error log. The display will confirm that the error log has been cleared by
displaying OK. The display will revert to the first log entry and show it as a null entry (1: ---).
If the QUICK START key is not held for a minimum of 4 seconds, the error log will not be
cleared.
26. Press the RESET key to exit the diagnostics display program.

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Procedure 2.3 - Accessing the Club Settings Display
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.
Procedure
1. With the PRECOR EFX banner displayed, press keys RESET,5,6,5,1,5,6,5 sequentially.
Diagnostics Test
Select Language
Select Units
Set Max. Workout Time
Set Max. Pause Time
Set Cool Down Time
Set Custom Courses (C556i Navy, only)
2. The display name “SELECT LANGUAGE” will be displayed, press the OK key to proceed
to the select units display or an , key to proceed to a different display
3. Use the , keys to scroll the list of languages, when the desired language is displayed
press the OK key to accept the desired language and exit the select language display.
4. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the select units
display.
5. The display name “SELECT UNITS” will be displayed, press the OK key to proceed to the
select units display or an , key to proceed to a different display.
6. One of two measurement standards will be displayed, U. S. Standard or Metric.
7. If U. S. Standard is selected, weights will be in pounds and distances will be in miles. If
Metric is selected, weights will be in kilograms and distances in kilometers.
8. Pressing any , key will toggle the units of measure between US Standard and Metric.
9. Press the CANCEL (C532i) or the BACK (C556i Navy) key to proceed to the set max
workout time display.
10. The display name “SET MAX WORKOUT TIME” will be displayed, press the OK key to
proceed to the set max pause time display or an , key to proceed to a different display.
11. The current workout time will be displayed. Pressing any , key will increase or decrease
the maximum pause time between 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.

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13. The display name “SET MAX PAUSE TIME” will be displayed, press the OK key to proceed
to the set max pause time display or an , key to proceed to a different display.
14. The current pause time will be displayed. Pressing any , key will increase or decrease
the maximum pause time between 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.
17. The current cool down time will be displayed. Pressing any , key will increase or
decrease the cool down time between 0 and 5 minutes.
18. Press the BACK key (C556i Navy) to proceed to the set custom courses display or the
Cancel key (C532i) to exit the set cool down display, skip to step 22.
19. Press the OK key to enter the set custom courses display.
20. Press the BACK key to exit the set custom courses display
21. Press the RESET key to exit the set user parameters program.

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Procedure 2.4 - Documenting Software Problems
When a problem is found with either the software or upper or lower PCA’s, record the information
listed below. If you 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:
• Model and serial number
• Software version numbers for upper and lower PCA’s
• User and program number running when the problem occurred
• A description of:
a. What happened or failed to happen.
b. The action taken by the user just before the problem occurred.
c. 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.

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Procedure 2.5 - Uploading Upper PCA Software and Serial
Number Information
Using Windows CSAFE
T here are three ways to use Windows CSAFE.
First, you can use it as a query tool to send various CSAFE requests to the machine. When you
do this, the program responds with both the raw hexadecimal response, and the decoded
response.
Second, you can use the program to update (flash) the firmware of a machine.
Third, you can enter a fitness machine's serial number.
It should be noted that Windows CSAFE is not compatible with Windows Vista.
Use the options menu to set the COM port that you're using with the program. You may need to
do this only once, or you may need to do this each time you run the program, depending on your
computer.
You may also use the options menu to set the default a90 directory where you store your
firmware. This will facilitate the usage of different directories for consumer display software,
versus their commercial counterparts. Like the COM port settings, the program may or may not
remember your directory preference between runs.
There are 3 directories that were created for you during installation of the software. They are
underneath the same directory in which you installed the program. You'll find one each for
consumer, commercial, and experience line machines. The commercial folder is the default.
Uploading software and serial numbers into Upper PCA boards
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.
T ools Required
Laptop computer, data cable part number 47389-101, serial to RJ-45 connector adaptor, USB to
serial adapter (if necessary), WindowsCSAFE program (downloaded from Precor Connection
website). The RJ-45 connection for data that is on most laptops will not work.
Uploading software
Download the appropriate software from Precor Connection for Experience, Commercial, or
Residential. The Word document in the zip file will help you to choose the correct software for the
unit you are working on.

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Open the WindowsCSAFE program. It may be necessary to set program to find the file you want
to access. On the tool bar menu choose Options, then set a90 folder. In the box that opens,
locate the folder you downloaded the files to, then hit OK.
Now you should ensure that the COM port is properly set. Choose Options, then Set COM Port,
and choose the proper port from the drop down menu.
Using the drop down menu under Flash Firmware choose the correct file for the equipment you
are servicing. Ensure that the power to the lower pca is removed, and that the lower pca has no
residual power. Connect the data cable between the computer and the CSAFE port on the upper
pca.
Press the Flash button, the data box at the bottom of the screen will prompt that upload will occur
when the upper pca is powered. Apply power to the unit. The upper display should not illuminate,
if it does you don't have a proper connection between the computer and the upper pca, or the
lower board was not fully discharged. Check the COM port setting and the lower pca, then when
both are correct hit Flash again.
When the connection is properly made the data box will indicate that upload is in progress. The
Progress bar will show the progress of the upload, which may take as much as 5 minutes,
depending on the download speed of the computer.
When the upload is complete, disconnect the cable between the computer and the unit, and
power the unit down, allowing the lower board to completely discharge. Power up the unit, and
verify the software version from the display.
Uploading serial numbers
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.
1. Click on the WinCSAFE 2.0 icon to open the program.
2. Click on the Options tab and select the correct Com port.
3. Connect the cable from the computer's RS232 I/O port to the CSAFE port on the
equipment's upper pca.
4. Be sure to have the equipment powered up for the following steps. If the unit is a self-
powered unit, you must pedal the unit to provide power before the data will be written.
5. Enter the serial number data into the Set Serial Number window.
6. Click on the Send button to write the information into the equipment.
7. Using the standard diagnostics routine, verify that the serial number has been written to the
upper pca.
8. Once verified disconnect the cable from the upper pca.

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Section Three - Preventive Maintenance
Preventive maintenance measures are either scheduled or unscheduled. Scheduled preventive
maintenance activities are included here so that you are aware of the preventive measures to be
performed on a regular basis.
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.
Every Week
Wipe the surface of the electronic console with a slightly-damp sponge or soft cloth. Dry with a
clean towel.
CAUTION
Keep water away from electronic components to prevent shock.
On-Site Preventive Maintenance (Service Technician)
Perform the following preventive maintenance tasks each time you are called to service a EFX:
Examine the belts for wear, cracks or other signs of deterioration and replace if necessary.
Check the LED’s mounted on the upper PCA and the function keys displayed on the electronic
console by performing Procedure 2.1.
Visually examine all wires and check connectors and wire connections. Secure connections and
replace wiring as necessary.
Check unit operation per Section Four.

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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
1. Start striding on the EFX or plug the optional external power supply (when available) into the
EFX and the AC outlet.
2. Press QUICK START.
3. Select Resistance Level 1.
4. Operate the EFX for 4–5 minutes. As you operate the EFX, concentrate on the operating
sounds made by the unit. Be on the alert for unusual rubbing, hitting, grinding, or squeaking
noises.
5. If the EFX makes unusual noises or the electronic display does not change appropriately,
troubleshoot per section 6.4.
6. Press the RESISTANCE key until you reach Resistance Level 10. Operate the EFX for
another 2–3 minutes.
7. If the EFX resistance does not change or the operation of the EFX feels inconsistent
compared with Resistance Level 1, troubleshoot per section 6.4.
8. Press the RESISTANCE key until you reach Resistance Level 20. Operate the EFX for
another 2–3 minutes.
9. If the resistance of the EFX does not change or the EFX operation feels inconsistent with
Resistance Levels 1 and 10, troubleshoot per Procedure 6.4.
10. Check the LED’s mounted on the upper PCA and the function keys displayed on the
electronic console by performing Procedure 2.1.
11. Thoroughly test all functions per Section Four.

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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
1. Remove the access cover, top cover, left and right side covers. See Procedure 7.1.
2. Remove the two screws that retain the black plastic shield. Remove the black plastic shield
from the EFX.
3. Remove the red battery lead from the lower PCA. See Diagram 5.1.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in Sec-
tion One, Things You Should Know.
4. Set the ohmmeter to a range that will conveniently read up to 50 Ω.
5. Remove the six phase generator connector from the lower PCA, refer to Diagram 5.1,
below.
6. With an ohmmeter, read between terminals 1 & 2, terminals 1 & 3, terminals 1 & 5, terminals
1 & 6, and terminals 1 & 7 on the six phase generator connector (J1). Each of the readings
should be between 36 Ω and 40 Ω.
7. If any of the readings are significantly high or significantly low, remove the intermediate
cable from the generator and perform the same measurements as in step 4 on the generator
connector. If the readings are now correct check and or replace the intermediate cable refer
to Diagram 5.1. If the readings are still incorrect, remove the six phase generator.
8. Replace the generator per Procedure 7.10. Reconnect the intermediate cable removed in
step 5 to the replacement generator and the lower PCA.
9. Reconnect the red battery lead to terminal M6 of the lower PCA.
10. Set the black plastic shield in its mounting position and fasten it with the screws removed in
step 2.
11. Set the right side of the rear cover in it’s mounting position and rotate it clockwise. Ensure
that the cover is fully engaged and fasten it with the screw removed in step 1.

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Diagram 5.1 - Lower PCA
Red
Battery
Connection
Generator
Connector
Load
Resistor
Connections
Cable
Lower
Interconnect

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Procedure 5.2 - Inspecting and Adjusting Belt Tension
Procedure
1. 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.
.
WARNING
If the EFX has been in recent use, the load resistors and mounting bracket may be extremely
hot.
2. Remove the two screws that retain the black plastic shield on the left side of the EFX.
Remove the black plastic shield from the EFX.
3. Place a automotive or equivalent belt tension gauge on the input belt as shown in Diagram
5.2.
Diagram 5.2 - Input Belt Tension Measurement
Left Side Adjustment Bolt