Precor Elliptical Fitness Crosstrainer EFX 5.25 User manual

5.23, 5.25 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.
© 2008 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20039-158

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
5.23, 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 5.23, 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 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, such as the power cord and on/
off switch 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/connection.

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
belt gauge (part # 20030-117)

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 Skeys, sequentially.
Diagram 2.1 - 5.25 Display

3. SERVICE MODE PRESS ENTER will scroll across the display.
4. The S,Tkeys 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.
9. If do you do not wish to restore the factory settings use the S,Tkeys 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 sequentially 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.

Procedure 2.2 - Accessing the Odometer & 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 Sand
RESISTANCE Tkeys, sequentially.
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.

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 Tand
RESISTANCE Skeys, sequentially.
3. UNIT CHANGE will be displayed.
4. Press a S,Tkey to view the currently selected unit of measure.
5. Press a S,Tkey 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.

Procedure 2.4 - Accessing the Production Check Mode
The production check mode moves the incline to level 8. Level 8 is the position the incline must
be in to be calibrated. See Procedure 5.3 for incline calibration details. The production mode also
provides a means of testing all of the display keys. This mode is used on the Precor production
line to set the incline calibration and 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 INCLINE T, RESET and
RESISTANCE Tkeys, sequentially.
3. 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. Note: if the incline was already
at level 8, the program will proceed directly to the production check mode. The incline is now
in the correct position to be calibrated. If incline calibration is required, see Procedure 5.3.
Incline calibration is typically only required after the incline motor has been replaced.
4. Once the incline has reachedlevel 8, PRODUCTION CHECK MODE - PRESS ENTER KEY
TO CHECK ALL KEYS will scroll across the lower display.
5. To exit the production check mode without checking the display keys, press the RESET key
or press the ENTER key to proceed with the key test.
6. 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.
7. 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.
8. If the key test is passed, press and hold the ENTER key to exit the production check mode.

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 S,Tkeys 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.

Procedure 2.6 - 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
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 frequency of occurrence.
• Contact precor technical support at 800-347-4404 to receive a return tag.

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
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.

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. 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 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 Skey 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 section 6.4.
8. Press the RESISTANCE Skey 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.

Procedure 5.1 - Measuring the Resistance of an Eddy Current
Magnet
Caution
Remove power from the EFX before you measure magnet resistance.
Procedure
1. Set the on/off switch in the “off” position, 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.
1. Remove the left and right side rear covers as described in Procedure 7.1.
2. Set the ohmmeter to a range that will conveniently read up to 125Ω.
3. Disconnect the J1 (magnet) connector from the lower PCA. Measure the resistance
between the two terminals of the connector removed from the lower PCA.
Diagram 5.1 - Eddy Current Magnet
Note:
The resistance of the magnets will be higher than optimum (90 - 110 Ω) when they are warm.
4. If the resistance measures significantly low or open, replace the magnet.
5. Re-install the rear covers as described in Procedure 7.1.
6. Set the on/off switch in the “on” position. Thoroughly test all functions per Section Four.
Eddy
Current
Magnet

Procedure 5.2 - Inspecting and Adjusting Belt Alignment and
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. Operate the unit by rapidly rotating a crankarm by hand. As the unit operates watch the
drive belts for proper alignment. The belts should operate parallel to each other and the
belts should maintain even spacing.
4. If the belts are not correctly aligned...
THEN... OTHERWISE...
Continue with the next step. Skip to step 13
5. Refer to Diagram 5.3 for the following belt alignment steps.The right and left step up belt
tension bolts have locking tabs. If necessary, use pliers to bend the locking tabs out of the
way so that the bolts can be turned.
6. If the step up pulley belt is out of alignment to the right, continue with step 8.
7. If the step up pulley belt is out of alignment to the left, continue with step 10.
8. Turn the left step up belt tension bolt 1/4 turn clockwise, then repeat step 4. If turning the left
adjustment bolt 1/4 of a turn was not sufficient, turn the right step up belt tension bolt 1/4 of
a turn counterclockwise.
9. Repeat step 6, alternating between the left and right step up belt tension bolts until the
alignment is correct. Continue with step 13.
10. Turn the right step up belt tension bolt 1/4 of a turn clockwise, then repeat step 4. If turning
the right step up belt tension bolt 1/4 of a turn was not sufficient, turn the left step up belt
tension bolt 1/4 turn counterclockwise.
11. Repeat step 11, alternating between the right and left step up belt tension bolts until the
alignment is correct.

12. Belt tension must now be checked and if necessary corrected. Remember, if it is necessary
to change belt tension, the belt alignment must be maintained.
Diagram 5.3 - Drive Unit
13. Place a belt gauge (McMaster-Carr 6160K12 or Grainger 3HX33) in the middle of the step
up belt at the center of the belt span (see Diagram 5.4). 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.
14. If the tension in step 14 is correct skip to step 18. Otherwise continue with the next step.
Input
Belt
Step Up
Belt
Tensioner
Input Belt
Step Up Belt
Tension Bolt
Input Belt
Tension Bolt
Adjustment
Slot
Idler Pulley
Mounting Bolt

Diagram 5.4 - Measuring Belt Tension
15. If the locking tabs on the right and left step up belt tension bolts have not been straightened,
use pliers to bend the locking tabs out of the way so that the bolts can be turned.
IF... THEN...
The belt tensioning gauge reads Turn both tension bolts
less than 14 pounds clockwise, in equal quarter-turn
increments, until the belt tensioning
gauge reads 14 - 16 pounds @1/4” deflection.
The belt tensioning gauge reads Turn both tension bolts
more than 16 pounds counterclockwise, in equal
quarter-turn increments, until the belt
tensioning gauge reads 14 - 16 pounds @ 1/4”
deflection.
16. Verify that the belt alignment is still correct by performing the procedure in step 4.
17. When both the step pulley belt tension and alignment are correct, use pliers to bend the
tension bolt locking tabs into the “locking” position.
18. The input pulley tension must now be checked and corrected, if necessary. There is not
sufficient room to use the belt tension gauge to set the input pulley belt tension. It will be
necessary to use the correctly tensioned step up belt as a comparison to set the input belt
tension.
19. Using your finger, press in on the center of the step up pulley belt to get a feeling of how
much pressure it takes to deflect the belt a 1/4”.
20. Using your finger, press in on the center of the lower span of the input belt. Compare the
pressure required to deflect the input belt to the pressure required to deflect the step up belt.
15 lbs
1/4”

21. Slide a stout screwdriver blade into the adjustment slot, See Diagram 5.3, to the upper left of
the idler pulley. Using the screwdriver as a lever, press the pulley down and to the right.
While maintaining constant pressure on pulley, check the belt tension with your finger.
When the belt tension feels correct, tighten and torque the input belt tension bolt to 200 inch
pounds (17 foot pounds).
22. Check drive input adjustment per Procedure 5.4.
23. Check the operation of the unit as described in Section Four, then re-install the rear cover
as described in Procedure 7.1

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 T, RESET and
RESISTANCE Tkeys, sequentially.
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.
Top Retaining
Bracket
Yoke Mounting
Bolts
Lift Nut
2-1/8”

12. Turning the lift nut as little as possible (only enough to allow it to align in the yoke) slide the
lift nut 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.