Precor Elliptical Fitness Crosstrainer EFX 5.25 User 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 re uired to perform the majority of troubleshooting, and
replacement procedures re uired 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

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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 5.25
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, the power cord must be disconnected from the wall outlet. Always
ensure that the EFX is unplugged from the wall outlet when you inspect or adjust the EFX, or when
you isolate, remove, or replace a 5.25 EFX 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.
• 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 li uids 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, such as the power cord and on/off
switch away from water and other li uids.

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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 Equip ent
The following list is a summary of the tools and e uipment re uired 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
Spares
rubber mallet data cables
snap ring pliers
100 ft./lb. torque wrench
500 in./lb. torque wrench
belt gauge

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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
1. Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch.
2. While pressing and holding the ENTER key, press the RESET, QUICK START and RESISTANCE 
keys, se uentially.

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Diagram .1 - 5. 5 Display
3. SERVICE MODE PRESS ENTER will scroll across the display.
4. The , keys move the selection between the Key Test, Factory Set and the Display Test.
Key Test
5. When Key Test is displayed, press the ENTER key to enter the key test mode.
6. Press each key on the display, the key name will be displayed when the key is functioning correctly.
7. Press and hold the ENTER key to exit the key test.
Factory Set
8. Factory set clears user parameters and returns all programs to the factory default settings.

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9. 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.
Display Test
11. Press the ENTER key to enter the display test.
12. The display will se uentially illuminate all of the L.E.D.’s on the display. The test will run
continuously until you exit the test.
13. Press the RESET key to exit the display test.
14. Press the RESET key to exit the service mode program.

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Procedure 2.2 - Accessing the Odo eter & Software
Versions
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch.
2. While pressing and holding the ENTER key, press the RESET. INCLINE  and RESISTANCE 
keys, se uentially.
3. The upper display screen will scroll the upper and lower software versions.
4. The lower display screen will scroll the total number of strides and the total number of operation
hours.
5. Press the RESET key to exit the odometer and software versions display.

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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.
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch.
2. While pressing and holding the ENTER key, press the RESET, INCLINE  and RESISTANCE 
keys, se uentially.
3. UNIT CHANGE will be displayed.
4. Press a , key to view the currently selected unit of measure.
5. Press a , key to toggle between U.S Standard and Metric units.
6. Press the RESET key to exits without saving the currently selected unit of measure or the ENTER
key to save the currently selected unit of measure.
7. Press the RESET key to exit the unit change mode.

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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.
1. Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch.
2. While pressing and holding the ENTER key, press the RESISTANCE , RESET and RESISTANCE 
keys, se uentially.
3. After you have entered the key test, it is necessary to press every key on the display before you can
exit the procedure. This ensures that all of the keys are functioning. If all of the keys are functioning
correctly, PASS will scroll across the upper display.
4. If the key test is failed, FAILED will scroll across the upper display and you will be unable to exit the
production check mode. Set the on/off switch in the off position. See Procedure 7.2 for display
front panel replacement.
5. If the key test is passed, press and hold the ENTER key to exit the production check mode.

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Procedure 2.5 - Accessing the Error Log
1. Plug the power cord into the wall outlet, then turn on the EFX with the on/off switch.
2. Press and hold the RESET key for four seconds.
3. ERROR LOG will scroll across the upper display.
4. If no errors are present in the error log, NO ERROR will scroll across the lower display.
5. If errors are present they will scroll across the lower display in the form 1 - ERROR XX AT XXX
STRIDES XX HOURS.
6. Use the , keys to scroll through the errors in the error log.
7. If you wish to clear the error log, press and hold the QUICK START key until CLEARED is displayed.
8. To exit the error log without clearing the log press the RESET key.

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Procedure 2.6 - Docu enting Software Proble s
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
Note:
Look at the PROM mounted on the upper PCA. A label on the PROM 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 fre uency of occurrence.
• Contact Precor technical support at 800-347-4404 to receive a return tag.

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Section Three - Preventative 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 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.
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 uick method of checking EFX operation. Check the operation of the
EFX at the end of all maintenance procedures.
Procedure
1. Plug the power cord into the wall outlet and set the on/off switch in the “on” position.
2. With the PRECOR EFX banner displayed, 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 s ueaking noises.
5. If the EFX makes unusual noises or the electronic display does not change appropriately,
troubleshoot per procedure 6.4.
6. Press the RESISTANCE key until you reach Resistance Level 8. 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 procedure 6.4.
8. Press the RESISTANCE key until you reach Resistance Level 16. 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 8, 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. Turn off the EFX with the on/off switch, then unplug the power cord from the wall outlet.

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Procedure 5.1 - Inspecting and Adjusting Belt Tension
Procedure
1. 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.
2. Remove the rear covers as described in Procedure 7.1.
3. Refer to Diagram 5.1 for the following belt tensioning steps.
Diagram 5.1 - Drive Unit
4. Place a belt gauge (McMaster-Carr 6160K12 or Grainger 3HX33) in the middle of the drive belt at
the center of the belt span (see Diagram 5. ). Lay a straight edge along the length of the belt and
beside the belt gauge. Slide one of the o-rings up against the shoulder of the belt gauge. Press
downward on the belt gauge, causing the belt to deflect. Read the deflection on the belt gauge at
the edge of the straight edge. Deflect the belt 1/4”. Read the tension across the top edge of the o-
ring. If the belt is correctly tensioned the gauge will read between 14 and 16 pounds.
5. If the tension in step 4 is correct skip to step 8. Otherwise continue with the next step.
Magnetic Brake
Drive Belt
Idler Pulley
Mounting Bolt
Idler Pulley
Adjustment Slot
Step Up Pulley
Idler Pulley
Tensioner Bolt

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Diagram 5. - Measuring Belt Tension
6. 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” deflection.
The belt tensioning gauge reads Turn the 8mm hex cap, idler pulley tension bolt
more than 16 pounds counterclockwise, in
quarter-turn increments, until the belt
tensioning gauge reads 14 - 16 pounds @ 1/4”
deflection.
7. When the drive belt tension is correct, re-tighten the idler pulley mounting bolt to 200 inch
pounds (17 foot pounds).
8. Check the operation of the unit as described in Section Four, then re-install the rear cover as
described in Procedure 7.1
15 lbs
1/4”

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Procedure 5.2 - Drive Input Asse bly Adjust ents
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.
1. 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.
2. Remove the rear covers as described in Procedure 7.1.
3. Remove both stairarms as described in Procedure 7.16.
Input Drive Assembly Axle Alignment
4. Rotate one of the crankarms to the twelve o’clock position and measure the distance from the
crankarm to the frame weldment. See Diagram 5.3. Rotate the opposite crankarm to the twelve
o’clock position and measure the distance from the crankarm to the frame weldment. If the two
measurements are different by more than 1/16 inch, continue with step 5.
Diagram 5.3 - Crankarm to Frame Weldment Measurements
5. On the side with the larger measurement, loosen the upper pillow block mounting bolt only, do not
loosen the lower pillow block mounting bolt. On the side with the smaller measurement, loosen
both pillow block mounting bolts. See Diagram 5.4. For purposes of illustration we will assume
that the left measurement was larger than the right side measurement in Diagram 5.4.
Measurement

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Diagram 5.4 - Pillow block Mounting Bolts
6. 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.
7. Tor ue the three loose pillow block mounting bolts to 120 inch pounds (10 foot pounds).
Loosen
Loosen
Loosen
Do not Loosen
Tap Here

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Procedure 5.3 - Calibrating the Lift Motor
1. In order to calibrate the lift motor, it is necessary to disconnect the lift motor from the ramp
assembly.
2. Set the on/off switch in the “off” position, remove the A.C. line cord from the A.C. outlet.
3. Remove the six screws from the rear of the front cover. Do not remove the two screws at the
bottom center of the rear cover and remove the front portion of the rear cover.
4. Remove the two screw from the top retaining bracket, remove the top retaining bracket. See
Diagram 5.5.
Diagram 5.5 - Lift Motor Mounting
5. Support the ramp. If the ramp is not supported it will fall during the next step.
6. Remove both yoke mounting bolts. Slide the lift motor out of the yoke.
7. Insert the A.C. line cord in the A.C. outlet, set the on/off switch in the “on” position.
8. While pressing and holding the ENTER key, press the INCLINE , RESET and RESISTANCE 
keys, se uentially.
9. LIFT CALBRATION - LIFT MOVING TO LEVEL 8 will scroll across the lower display and the incline
will move to level 8, if it is not currently at level 8.
10. Set the on/off switch in the “off” position.
11. Rotate the lift nut until the distance from the bottom edge of the lift nut to the top edge of the lift
motor drive screw is 2-1/8 inch. See Diagram 5.5.
12. Turning the lift nut as little as possible (only enough to allow it to align in the yoke) slide the lift nut
Top Retaining
Bracket
Yoke Mounting
Bolts
Lift Nut
2-1/8”

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into the yoke and fasten it with the bolts removed in step 6.
13. 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.
15. Set the on/off switch in the “on” position.
16. Thoroughly test all incline functions.