Precor C544 User manual

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C544 Elliptical Fitness Crosstrainer
Warning: This service manual is for use by Precor trained service providers only.
IfyouarenotaPrecorTrainedServicer,youmustnotattempttoserviceanyPrecorProduct;
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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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.
Warning and Caution Statements and General Safety Guidelines
Warning statements indicate a particularly dangerous activity. Warning statements you will find in
this manual include:
• To remove power from the EFX 544, the power cord must be disconnected from the wall
outlet. Always ensure that the EFX 544 is unplugged from the wall outlet when you inspect
or adjust the EFX 544, or when you isolate, remove, or replace an EFX 544 component.
• 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.
• When the EFX 544 is operating, the capacitor will hold a lethal amount of charge. Do not
touch the capacitor as serious injury or death might result.
• When the EFX 544 is turned off and the power cord is removed from the wall outlet, the
capacitor will hold voltage for 30–60 seconds. Allow the capacitor to discharge for a period
of one minute before you touch or work near the capacitor. Do not attempt to discharge the
capacitor by any other means.
• Exercise caution when touching any wire or electrical component during EFX 544 operation.
• Exercise extreme caution when working with the flywheels and/or the stairarms. Because of
the mass of the flywheels, serious injury may result if fingers are pinched between the
flywheel spokes and the stairarms.
• The flywheel is very heavy. Be prepared for the weight of the flywheel when it comes off of
the pulley shaft.
Caution statements are intended to prevent damage to the EFX 544 as a result of the current
activity. Caution statements included in this manual are listed below:
• Notice the orientation notch on the PROM (U3). These components must be positioned with
the same notch orientation.

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• When it is necessary to lift the EFX 544, ensure that the EFX 544 has adequate support. Do
not lift the EFX 544 by the front cross-member.
Safety guidelines you should know and follow include:
• Read the owner’s manual and follow all operating instructions.
• Operate the EFX 544 on a solid, level surface. Locate the rear of the EFX 544 at least four
feet from walls or furniture. Keep the area behind the EFX 544 clear.
• Visually check the EFX 544 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 544.
• When operating the EFX 544, 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 544.
• To prevent electrical shock, keep all electrical components, such as the power cord and
circuit breaker away from water and other liquids.
• 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”.

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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. In using the standardized access codes the keys are
numbered left to right with key #1 on the far left and key #7 on the far right. If the standard access
codes do not function on the unit being tested refer to the appropriate old access codes listed
below. The standard access codes use all sequential key presses, the old access codes use
simultaneous key presses.
Standard Access Codes
Diagnostics Keys RESET,5,1,7,6,5,7,6,1
Odometer Keys RESET,6,5
Club Settings Keys RESET,5,6,5,1,5,6,5
Old Access Codes
Diagnostics Keys Ramp ▲, Resistance ▼, Resistance ▲
Odometer Keys Ramp ▲, Resistance ▲
Club Settings Keys Resistance ▲, Quick Start/Change

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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
• Performing the Keypad Test
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX 544 with the circuit breaker.
2. Press the RAMP ▲,RESISTANCE ▼and RESISTANCE ▲ keys, simultaneously or keys
RESET,5,1,7,6,5,7,6,1, sequentially.
3. Watch the upper display as the LED test progresses. The test is programmed to display the
following LED illumination sequence:
a Every LED on the left display window illuminates simultaneously.
b Diagonal lines of illuminated LED’s sweep across the left display window.
c The right display windows illuminate, then decrement from 8.8.8.8 to 0.0.0.0.
d The function LED’s illuminate simultaneously and then extinguish.
e Each function LED illuminates separately and then extinguishes.
4. With LIFT displayed in the right display window, watch the right display window (shown in
Diagram 3-1). Press the RAMP ▲and RAMP ▼keys. Verify that the lift calibration number
increments and decrements as the RAMP keys are pressed.
5. If you do not observe the LED illumination sequences described in Step 3...
THEN... OTHERWISE...
Replace the upper PCA as described The LED passed successfully;
in Procedure 8.2. continue with the next step.

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Diagram 3.1 - C544 Display
6. Press ENTER, then release.
7. 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. A label on U3 indicates the software version number. The part
number of the PROM indicates the version number.
8. Press ENTER, then release.
9. With HArt displayed in the right display window, a heart rate will be displayed when a chest
strap or test transmitter is used.
10. Press ENTER until seven dots illuminate in the left display window.
11. Press each key listed below. Verify that each single dot expands to four dots as the
appropriate key is pressed.
ENTER Expands the far left dot.
RAMP DOWN Expands the second dot from the left.
RAMP UP Expands the third dot from the left.
STOP/RESET Expands the center dot.
RESISTANCE DOWN Expands the third dot from the right.
RESISTANCE UP Expands the second dot from the right.
QUICK START Expands the far right dot.

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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.

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Procedure 3.3 - Displaying the Odometer
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX 544 with the circuit breaker.
2. With the PRECOR EFX 544 banner scrolling, press the RAMP ▲and RESISTANCE ▲
keys, simultaneously or keys RESET,6,5, sequentially. The messageEFX 544 ODOMETER
will scroll across the left display window.
3. Press ENTER, then release.
Note:
The right display window displays the total strides on the EFX 544 (see Diagram 3.2). The
number displayed is 102,187. To convert strides to miles, divide the total number of strides by
2241. To convert strides to kilometers, divide the total number of strides by 1392.5.
Diagram 3-2. - Odometer Reading
8712 10

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Procedure 3.4 - Club Settings
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. Plug the power cord into the wall outlet, then turn on the EFX 544 with the circuit breaker.
2. 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.
Standard or Metric will scroll across the display.
3. If you wish to change the measurement standard...
THEN... OTHERWISE...
Use the ▲or ▼keys to toggle Continue with the next step.
to an alternate measurement standard;
then continue with the next step.
4. Press ENTER, then release.
5. Either 120 VOLTS or 240 VOLTS will scroll across the display. Press either of the ▲ or ▼
keys to toggle between the 120 0r 240 volt setting.
Note:
The 120 Volt/240 Volt setting does not change the input operating voltage of the EFX 544. It
changes the resistance levels to match the input operating voltage. Therefore, this setting must
match the input voltage of the EFX 544. If the setting does not match the input voltage, the
resistance levels will be incorrect.
6. The maximum workout time is displayed on the left display window.
7. If you wish to change the maximum workout time...
THEN... OTHERWISE...
Use the ▲or ▼keys to select Press ENTER to continue with the next step.
the new maximum workout time;
then continue with the next step.
8. Either SMART RATE ACTIVATED or NO SMART RATE will scroll across the display. Use
the ▲ or ▼ keys to activate or deactivate smart rate, as required. Press ENTER to exit.

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Procedure 3.5 - 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 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 number
Note:
Look at the PROM (U3) mounted on the upper PCA. A label on U3 indicates the software version
number. The part number of the PROM indicates the version number.
• 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.