Precor C546 User manual

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C546 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
C546 Serial Codes and Manufacturing Dates
The C546 has been manufactured in three versions. The applicable serial codes and
manufacturing dates associated with each version will be detailed below. When servicing a C546
it is critical that you are aware of which version of C546 you are servicing. The differences in the
versions may greatly impact service requirements and procedures. For convenience, the
versions detailed below will be referred to as version 1, version 2 or version 3 in the reminder of
this service manual. Any procedures that do not reference a specific version is applicable to all
versions of the C546.
Version 1 was manufactured between March 1998 and September 2000. The serial codes
associated with version 1 are 4H, 4K, 4L, 4J, 4M, 4N, 4P, 4R, 4S, 4T, 4U, 4Q, 4V, 4X, 4Y, 4W,
4Z, 5A, 5V, 5W, 5X and H9.
Version 2 was manufactured between July 2000 and August 2001. The serial codes associated
with version 2 are 69, 75, 8N, 9A, 9B, 9K, AP, AS, AT, AY, AX, AZ, BL, BM, BN, BP, BR, BT, BW,
BY, CA, CB, CC, CD and CE.
Version 3 was manufactured between August 2001 and the present. The serial codes
associated with version 3 are DC, DE, EX, GT and GU.
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
546, 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 an 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.

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• A pinching hazard exists when the unit is operated by turning the crankarms by hand. It is
possible to seriously pinch a finger between the crankarm and stairarm. The stairarms
should be removed before operating the crankarms by hand.
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 PROM. These components must be positioned with the
correct notch orientation.
• When it is necessary to lift or move the EFX, ensure that the EFX has adequate support and
that you use proper lifting techniques.
Safety guidelines you should know and follow include:
• Read the owner’s manual and follow all operating instructions.
• Operate the EFX on a solid, level surface.

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• 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, while performing service. A water bottle holder is furnished as standard
on the EFX 546.
• 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
On units manufactured prior to August 16, 1998 a single lift connector (J4) was used. On
subsequent units the lift motor wiring is in the J3 connector and the lift potentiometer wiring is in
the J4 connector. This text will use the connections used on current production units. For units
manufactured prior to August 16, 1998, convert the lift connections as shown:
CONNECTION 8/16/98 AND LATER CONNECTION PRIOR TO 8/16/98
J3 terminal 1 J4 terminal 1
J3 terminal 2 J4 terminal 2
J3 terminal 3 J4 terminal 3
J4 terminal 1 J4 terminal 4
J4 terminal 2 J4 terminal 5
J4 terminal 3 J4 terminal 6
For the latest exploded view, part number and part pricing information, visit the Precor dealer
website at “www.precor.com/Dealer.
Tools Required
Multimeter Allen wrench set
Anti-static kit Screwdriver set
4” - 6” gear puller Straight edge
“C” clamp or Carpenter’s clamp Precor part number 20030-117 belt gauge
US and metric end wrench set
US and metric socket wrench set
Torque wrench, 200 in/lbs.

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Section Two - Preventive Maintenance
Preventive maintenance measures are either scheduled or unscheduled. Scheduled preventive
maintenance activities are included here so that you are aware of preventive measures
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.
After Each Use
• Turn off and unplug the EFX.
• Wipe down the covers, handlebars, stairarm wheels and stairarm ramps with a damp cloth.
Daily Maintenance
Clean the EFX’s frame, covers, stairarms, stairarm ramps and stairarm wheels using water or
“Simple Green”. Wipe the surface of the electronic console with a damp sponge or soft cloth. Dry
with a clean towel. “Simple Green” is the only cleaning solution that has been tested and
approved for use on the C546 ramps. Use of any other cleaner, may cause degradation of the
ramp anodizing and void the ramp warranty. The use of an acid (citric) based cleaner will cause
ramp anodizing damage and is not authorized by Precor.
Weekly Maintenance
• Vacuum underneath the EFX, following these steps:
1. Turn off the EFX with the circuit breaker, then unplug it from the wall outlet
2. Place the EFX on its side.
Note:
Place a drop cloth under the EFX to protect the flooring and to ensure that the EFX handrail
is not scratched or damaged.
3. Vacuum the rug or damp mop the floor.
4. Make sure that the floor is dry before returning the EFX to an upright position.

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Quarterly Maintenance
1. Remove front and rear covers.
2. Clean and lubricate the lift motor drive screw with bearing grease.
3. Check the step up and input belt tension as in Procedure 5.3.
4. Replace both covers.
On-Site Preventive Maintenance (Service Technician)
When you are called to service a EFX, perform these preventive maintenance activities:
• Perform the software diagnostics. Check LED and keypad function. Record the odometer
reading.
• Check speed sensor function (is the stride rate displayed when the unit is in operation?). If
not, see Procedure 6.4
• Does the ramp (lift) operate smoothly and quietly? If not, see Procedure 6.5.
• Visually inspect the drive belts for cracks, fraying or excessive wear.
• Inspect the power cord. If the power cord is damaged, install a new power cord.
• Visually examine all wires and check connectors and wire connections. Secure connections
and replace wiring as necessary.
.

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Procedure 3.1 - Software Access Codes
The C546 uses the standard access codes to provide access to the various software features. In
using the standardized access codes the keys are hypothetically numbered left to right with key
#1 on the far left and key #7 on the far right. The standard access codes use all sequential key
presses. The allowable delay between key presses is short. If too much time is taken between
key presses the access procedure will be aborted. If the access is aborted, it will be necessary to
start over from the beginning. See Diagram 3.1.
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

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Procedure 3.2 - Accessing the Diagnostic Program (version
1)
The EFX diagnostic software cycles through the following tests:
• LED Diagnostics
• Power Bits
• Lift Calibration Number
• Heart Rate
• Keypad Test
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker.
2. Press keys RESET,5,1,7,6,5,7,6,1., sequentially.
3. Watch the upper display as the LED test progresses. The test will illuminate every LED on
the display. The test will illuminate the LED’s in a specific pattern. When you are familiar
with the pattern, it is easy to determine when a LED does not illuminate.
4. If you do not observe the LED illumination sequences described in Step 3...
THEN... OTHERWISE...
Replace the upper PCA as described The LED test passed successfully;
in Procedure 7.2 or 7.3. continue with the next step.
5. Power Bits will be displayed. Power bits indicates the amount of power being applied to the
eddy current magnets and will vary directly with the resistance. Press ENTER to continue.
6. With LIFT displayed in the right display window, watch the right display window (shown in
Diagram 3.1). Press the CROSSRAMP ▲or CROSSRAMP ▼keys one at a time. Verify that
the lift calibration number increments or decrements as each of the CROSSRAMP keys are
pressed.

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Diagram 3.1 - C546 Display
7. Press ENTER, then release.
8. With HArt displayed in the right display window, a heart rate will be displayed when a chest
strap or test transmitter is used and the optional heart rate receiver has been installed in the
EFX.
9. Press ENTER until seven dots illuminate in the left display window.
10. 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.
CROSSRAMP DOWN Expands the second dot from the left.
CROSSRAMP 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.
Key #7
Key #1

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11. If the left display window column illuminates appropriately as each key is pressed...
THEN... OTHERWISE...
The keypad test passed successfully; Troubleshoot per Procedure 6.2 or 6.3
continue with the next step.
12. End the keypad test by pressing the CROSSRAMP ▼and RESISTANCE ▲keys
simultaneously.