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.

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Procedure 3.3 - Accessing the Diagnostic Program
(version 2,3)
The EFX diagnostic software cycles through the following tests:
• Display Test
• Keyboard Test
• Heart Rate
• Lift Calibration
• Brake 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. The message DISPLAY TEST will be displayed.
4. All of the LED’s on the display will be illuminated. Check to ensure that all of the LED’s are
illuminated.
5. Press the ENTER key to continue to the next test.
6. The message KEYBOARD TEST will be displayed.
7. The display will light two dots for each key on the display. When a key is pressed the upper
of the two lights will go out. Check each key position to ensure that all keys are functioning
normally.
8. Press and hold the ENTER key to continue to the next test.
9. The message HEART RATE TEST will be displayed.
10. Three heart rate readings will the be displayed. They will be from left to right, unfiltered,
filtered and polar readings. They will be designated U,F and P, respectively.
11. Press the ENTER key to continue to the next test.

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Diagram 3.1 - C546 Display
12. The message LIFT TEST will be displayed.
13. The display will read INCLINE followed by the incline setting and A/D followed by the analog
to digital lift number (lift calibration number). When the lift is operated, the incline position
should change and the A/D number should track the incline position.
14. The A/D number should range between approximately 94 and 209.
15. Press the ENTER key to continue to the next test.
16. The message BRAKE TEST will be displayed.
17. The display will the read LEVEL followed by the resistance level and BRAKE followed the
the power bits number. When the resistance level is changed, the level should change and
the power bits number (brake) should track the resistance level.
18. The brake level should range between approximately 0 and 89.
19. Press the ENTER key to exit the diagnostics program.
Key #7
Key #1

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Procedure 3.4 - Displaying the Odometer (version 1)
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker.
2. With the PRECOR EFX 546 banner scrolling, press keys RESET,6,5, sequentially until the
message EFX 546 ODOMETER scrolls across the display window.
3. Press ENTER, then release.
Note:
The right display window displays the total strides on the EFX 546 (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
000
0
0010
218
7

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4. Press ENTER, the software version and part number of the PROM will be displayed.
Note:
If you cannot determine the software version number in this manner, look at the PROM mounted
on the upper PCA. A label on the PROM indicates the software version number.
5. Press ENTER, to exit.

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Procedure 3.5 - Displaying the Odometer (version 2,3)
Procedure
1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker.
2. With the PRECOR EFX 546 banner scrolling, press keys RESET,6,5, sequentially.
3. The message ODOMETER will be displayed.
4. The display will then read XXXXXXXX STRIDES. Where XXXXXXX is the total number of
strides accumulated on the EFX.
5. Press the ENTER key to continue.
6. The message HOUR METER will be displayed.
7. The display will then read XXXX HOURS. Where XXXX is the total number of hours the unit
has been in operation.
8. Press the ENTER key to continue.
9. The message SOFTWARE VERSION will be displayed.
10. The display will then read UPPER X.XX and LOWER X.XX. Where X.XX is the software
version number. Both the upper PCA software version and lower PCA software version
numbers are displayed.
11. Press the ENTER key to continue.
12. The message ERROR LOG will be displayed.
13. The display will then show the log position number in the upper (heart rate) display window,
the error code in the middle (large) window and the stride count and hour meter reading
when the error occurred in the lower window. Log position 1 will be the most recent error
logged.
14. Press the ENTER key to exit the odometer program.

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Procedure 3.6 - Club Settings (version 1)
1. Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially.
2. The maximum workout time will be displayed. The maximum workout may be selected with
either of the ▲ or ▼ keys. Press ENTER to continue.
3. The maximum workout time is displayed on the left display window. The maximum workout
time is the maximum time a user is allowed to use the unit.
4. The maximum workout time is adjustable between 10 and 240 minutes. If you wish to
change the maximum workout time...
THEN... OTHERWISE...
Use the ▲or ▼keys to select Continue with the next step.
the new maximum workout time;
then continue with the next step.
5. Press ENTER, to continue.
6. The pause time will be displayed. The pause time is the length of time from the point that the
PAUSE key is pressed until the unit resets to the start up point if the unit is left inactive. The
pause time is adjustable between 1 and 120 seconds.The pause time may be selected with
either of the ▲ or ▼ keys. Press ENTER to exit.

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Procedure 3.7 - Club Settings (version 2,3)
1. Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially
2. The message SELECT LANGUAGE will be displayed.
3. Use the ▲, ▼keys to select the language to be displayed.
4. When the desired language has been selected, press the ENTER key to continue.
5. The message SELECT UNITS will be displayed.
6. Use the ▲, ▼keys to select the unit of measure to be displayed.
7. When the desired unit of measure has been selected, press the ENTER key to continue.
8. The message SELECT MAXIMUM WORKOUT TIME will be displayed.
9. Use the ▲, ▼keys to select the maximum workout time to be displayed. The maximum
workout time sets the maximum amount of time the user can remain in a course.
10. When the desired maximum workout time has been selected, press the ENTER key to
continue.
11. The message SELECT MAXIMUM PAUSE TIME will be displayed.
12. Use the ▲, ▼keys to select the maximum pause time to be displayed. The maximum pause
time sets the amount of time the unit will remain in the pause mode before it resets to the
start up banner.
13. When the desired maximum pause time has been selected, press the ENTER key to exit the
club settings program.

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Procedure 3.8 - 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 mounted on the upper PCA. A label on the PROM indicates the software
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.

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Section Four - Checking EFX 546 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. When the PRECOR EFX 546......WORK OUT SMARTER banner scrolling, press QUICK
START.
3. If the ramp is not currently at the mid-point, the ramp will automatically move to the mid-
point.
4. Select Resistance Level 1 and press ENTER.
5. 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.
6. If the EFX makes unusual noises or the electronic display does not change appropriately,
troubleshoot per Section 6.
7. Press the RESISTANCE ▲ key until you reach Resistance Level 10. Operate the EFX for
another 2–3 minutes.
8. If the EFX resistance does not change or the operation of the EFX feels inconsistent
compared with Resistance Level 1, troubleshoot per Section 6.
9. Press the RESISTANCE ▲ key until you reach Resistance Level 20. Operate the EFX for
another 2–3 minutes.
10. If the resistance of the EFX 546 does not change or the EFX operation feels inconsistent
with Resistance Levels 1 and 10, troubleshoot per Procedure 6.6.
11. Check the LED’s mounted on the upper PCA and the function keys displayed on the
electronic console by performing Procedure 3.2.
12. Press the CROSSRAMP ▲key while viewing the electronic console. Confirm that the foot
pads incline and the ramp display increments to 20 as the CROSSRAMP ▲key is pressed.
13. Press the CROSSRAMP ▼ key while viewing the electronic console. Confirm that the foot
pads return to a level position and the ramp display decrements to 1 as the CROSSRAMP ▼
key is pressed.

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14. If the ramp system of the EFX 546 does not operate properly, troubleshoot per Procedure
6.5.
15. Turn off the EFX with the circuit breaker, then unplug the power cord from the wall outlet.