Precor C546i User manual

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C546i Self Powered Elliptical Fitness Crosstrainer
(version 2, serial codes AA32, AAAJ, ADEE)
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.

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© 2004 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 C546i
facing the display enclosure.
General System Information
• The generator performs three functions in the EFX. First, by controlling the amount of
electrical load applied to the generator, the user’s pedalling resistance is controlled.
Second, the generator is used to charge the EFX’s internal battery. Lastly, one of the
generators six phase output windings is monitored to determine when the unit is in use and
when it is idle. This system also determines the stride rate by determining the operating
speed (output frequency) of the monitored generator winding.
Warning and Caution Statements and General Safety Guidelines
Warning statements indicate a particularly dangerous activity. Warning statements you will find in
this manual include:
• If the EFX has been in recent use, the load resistors and load resistor mounting bracket may
be extremely hot.
• Because this is a self powered unit, it will either be necessary to either equip the unit with
the optional external power supply or have an assistant pedal on the unit while voltage
measurements are being taken. Because of the danger of working on the unit while it is in
motion using the optional external power supply is strongly recommended.
• When the unit is used, stairarms are in motion, the generator will operate and produce
potentially hazardous voltages even when the battery is disconnected.
• To remove power from the EFX, the optional external power supply (when equipped) must
be disconnected from the wall outlet and the red (positive) lead must be disconnected from
the battery. Always ensure that the EFX external power supply is unplugged from the wall
outlet and the red (positive) lead is removed from the battery 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
cover(s) removed.
• During service operations you will be very close to moving machinery and voltage bearing
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.

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• Exercise caution when touching any wire or electrical component during EFX operation.
• 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:
• 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.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.
• To prevent electrical shock, keep all electrical components 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”.
Tools Required
Multimeter Allen wrench set
Anti-static kit Screwdriver set
4” - 6” gear puller 7/16” allen key, socket wrench mounted
Precor part number 20030-108 belt gauge Straight edge
US and metric end wrench set
US and metric socket wrench set
Torque wrench, 200 in./lbs.
Torque wrench, 200 ft./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
• Unplug the optional external power supply (when equipped) from the AC outlet.
• 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 a
30:1 solution of Simple Green®and water. Wipe the surface of the electronic console with a
damp sponge or soft cloth. Dry with a clean towel. A 30:1 solution of Simple Green®and water is
the only cleaning solution that has been tested and approved for use on the C546i 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.Unplug the optional external power supply (when equipped) from the AC 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 the rear covers.
2. Check the step up and input belt alignment and tension as in Procedure 5.3.
3. Replace the rear cover.
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, refer to Procedure 6.3
• Visually inspect the drive belts for cracks, fraying or excessive wear.
• When furnished, inspect the optional power supply cords. If a power supply cord(s) is
damaged, install a new power supply.
• 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 C546i 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. Refer to Diagram 3.1. The C546i display does not utilize key
positions #2 and #3, however, they must be counted to correctly locate keys #4 through #6. On
the C546i display key #1 is the RESET key and key #4 is the QUICK START key.
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
The EFX diagnostic software cycles through the following tests:
• Display Test
• Keyboard Test
• Heart Rate Test
• Battery Test
•RPMTest
• Lift Test
• Brake Test
Procedure
1. Start pedalling and continue to pedal as you perform step 2.
2. Press keys RESET,5,1,7,6,5,7,6,1., sequentially.
3. The message HARDWARE VALIDATION will be displayed for a few seconds.
4. The message DISPLAY TEST will be displayed followed by every LED on the display being
illuminated. Check each LED segment to ensure that all of the segments are illuminated.
Press the ENTER key to advance to the keyboard test.
5. The message KEYBOARD TEST will be displayed followed by a graphical representation of
each key position on the display housing. As each key on the display is pressed the key
representation is turned “off”, indicating that the key is functioning. Check each key in this
manner, including the numeric keyboard. Press and hold the ENTER key for 2 seconds to
advance to the heart rate test.
6. The message HEART RATE TEST will be displayed followed by the unfiltered (U), filtered
(F) and polar (P) heart rate readings if the heart rate option is installed in the C546i and a
chest strap transmitter or a test transmitter is being used. If the heart rate option is not
installed in the C546i, the message NO HEART RATE RECEIVER will be displayed instead
of the heart rate readings. Press the ENTER key to advance to the battery test.
7. The message BATTERY TEST will be displayed followed by the battery voltage. Press the
ENTER key to advance to the RPM test.
8. The message RPM TEST will be displayed followed by the pulse (power bit) reading and the
RPM reading. Press the ENTER key to advance to the incline test.
9. The message LIFT TEST will be displayed followed by the ramp incline position displayed
on the left and the A/D number (incline calibration number) displayed on the right. Press the
ENTER key to advance to the brake test.

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10. The message BRAKE TEST will be displayed followed the resistance level and brake level
readings. This test allows you to test the brake (resistance) at each resistance level. Press
the ENTER key to exit the diagnostics program.

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Procedure 3.3 - Displaying the Odometer
Procedure
1. Start pedalling and continue to pedal as you perform step 2.
2. With the PRECOR C546i banner scrolling, press keys RESET,6,5, sequentially.
3. The message INFORMATION DISPLAY will be displayed for a few seconds.
4. The message ODOMETER will be displayed followed by the total number of strides
accumulated. Press the ENTER key to advance to total strides.
5. The message TOTAL STRIDES will be displayed followed by the total number of strides
logged on the C546i. Press the ENTER key to advance to hour meter.
6. The message HOUR METER will be displayed followed by the total number of hours that
the C546i has been in use. Press the ENTER key to advance to software version.
7. The message SOFTWARE VERSION will be displayed followed by the upper software part
number UPPER APP XXXX-XXX. Use the and keys to display the boot software part
number UPPER BOOT XXXXX-XXX and lower software part number
LOWER XXXXX-XXX. Press the ENTER key to advance to error log.
8. The message ERROR LOG will be displayed followed by the error in log position 1. Each
log entry shows the log position, the stride count when the error occurred and the hour
meter when the error occurred. For example; 1 ER21 123456 STR 45678 HRS. The error
log can record up to ten error conditions. The error code in position one will be the most
recent error and the error in position ten will be the oldest error. If more than ten errors have
been logged, only the ten most recent will be displayed. Use the and keys to move
through the log. Pressing and holding the QUICK START key for four seconds will clear the
log. Press the ENTER key to advance to the serial number display.
9. If a serial number has been entered it will be displayed otherwise NO SERIAL NUMBER will
be displayed. Press the ENTER key to exit the odometer program.

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Procedure 3.4 - Club Settings
1. Start pedalling and continue to pedal as you perform step 2.
2. Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially.
3. The message SET CLUB PARAMETERS will be displayed for a few seconds.
4. The message SELECT LANGUAGE will be displayed followed by the currently selected
language. Use the  and  keys to select the language preference. Press the ENTER
key to advance to units of measurement.
5. The message SELECT UNITS will be displayed followed by the currently selected unit of
measurement. Use the  and  keys to select either U.S. Standard or METRIC
measurements. Press the ENTER key to advance to maximum workout time.
6. The message SET MAX WORKOUT TIME will be displayed followed by the currently
selected maximum workout time. Use the  and  keys to select the maximum workout
time. The maximum workout time may be set between 1 and 240 minutes or no limit. Press
ENTER to advance to maximum pause time.
7. The message SET MAX PAUSE TIME will be displayed followed by the currently selected
maximum pause time. Use the  and  keys to select the maximum pause time. The
maximum pause time is the that will elapse after the pause key has been pressed until the
unit resets. The maximum pause time may be set between 1 and 120 seconds. Press
ENTER to advance to set cool down time.
8. The message SET COOL DOWN TIME will be displayed followed by the currently selected
cool down time. Use the  and  keys to select the cool down time. Cool down time is
the period of time following the completion of a program for the user to cool down at a
reduced work rate. Press ENTER to advance to modify custom programs.
9. The message MODIFY CUSTOM COURSE 1 will be displayed. The modifications
instructions will then be displayed. Press ENTER to save custom course modifications and
to exit club settings program.

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Procedure 3.5 - Documenting Software Problems
When a problem is found with either the upper software or lower PCA’s, record the information
listed below. Refer to Procedure 3.6 to install new upper software. Please note, installing new
upper software is only appropriate if a later software version containing a correction for the
problem experienced is available. If an appropriate software version is not available the
information below must be forwarded to Precor customer support. This information will be used
to correct and create new software, whenever it is appropriate. Lower software is “firmware”. The
PROM in the lower PCA must be replaced to install new lower software, refer to Diagram 6.4.
When a problem occurs, record the following information:
• Model and serial number
• Software part numbers
• 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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Procedure 3.6 - Software Uploading Procedure
This unit utilizes an upper PCA software system that is capable of on site upper PCA software
uploading (re-programming). The software upload may be accomplished with the use of a PDA
(palm device) or a laptop computer.
If a palm device is to be used it must use OS software version 3.2 or higher. Currently, we have
only tested devices manufactured by Palm, but other manufacturer’s palm devices may also
function correctly.
If a palm device is to be used, the appropriate software must be available in the palm device. A
PDA containing the appropriate software may be ordered from Precor or it may be downloaded
to the PDA from your desktop or laptop computer via the “hot sync” function. With the PDA
inserted in the hot sync cradle, download to “Precor IFP” (in field programmer) directory.
If a laptop computer is to be used, the computer’s DB9 serial port will be used for the upload.
Upload Procedure
1. The EFX must be “powered down” before the upload procedure can be initiated. Ensure
that the EFX has not be used for a sufficient time to allow the lower PCA to completely
discharge. The light emitting diode on the lower PCA will go out when the power supply is
discharged.
2. If the CSAFE port is in use, temporarily disconnect the RJ-45 cable from the CSAFE port. If
the CSAFE port is not in use, temporarily remove the plastic plug from the CSAFE port.
3. Connect the PDA or computer interface cable to the CSAFE port.
4. Select the software file to be uploaded on the palm device or computer.
5. Start pedaling the EFX or power up using the external power supply. When the EFX “powers
up” the upload will commence. You must continue to pedal until the upload is complete,
approximately 2 minutes.
6. Stop pedaling or disconnect the external power supply when the upload is complete, and
allow the lower PCA to completely discharge. The light emitting diode on the lower PCA will
go out when the power supply is discharged.
7. Start pedaling the EFX, after it has been allowed to power down, the EFX will now be
operating on the newly uploaded software.
8. Thoroughly, check the EFX’s function per Section Four.

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Section Four - Checking C546i 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. Start striding on the C546i or plug the optional external power supply (when available) into
the EFX and the AC outlet.
2. When the PRECOR banner displayed, press QUICK START.
3. Select Resistance Level 1 and press ENTER.
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.
6. Press the RESISTANCE key until you reach Resistance Level 10. 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.
8. Press the RESISTANCE key until you reach Resistance Level 20. Operate the EFX for
another 2–3 minutes.
9. If the resistance of the C546i does not change or the EFX operation feels inconsistent with
Resistance Levels 1 and 10, troubleshoot per Procedure 6.6.
10. Check the LED’s mounted on the upper PCA and the function keys displayed on the
electronic console by performing Procedure 3.2.
11. 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.
12. 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.
13. If the incline system of the C546i does not operate properly, troubleshoot per Procedure 6.6.

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Procedure 5.1 - Measuring the Resistance of a Generator
Caution
If a external power supply is connected to the EFX, disconnect the external power supply from
the EFX before continuing with this procedure.
Procedure
1. Remove the screw at the right rear of the rear cover. Grasp the right side of the rear cover
and rotate it counterclockwise to remove the cover. Refer to Procedure 7.1.
2. Remove the two screws that retain the black plastic shield. Remove the black plastic shield
from the EFX.
3. Remove the red battery lead from the lower PCA. See Diagram 5.1.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.
4. Set the ohmmeter to a range that will conveniently read up to 50 Ω.
5. Remove the six phase generator connector from the lower PCA, refer to Diagram 5.1,
below.
6. With an ohmmeter, read between terminals 1 & 2, terminals 1 & 3, terminals 1 & 5, terminals
1 & 6, and terminals 1 & 7 on the six phase generator connector (J1). Each of the readings
should be between 36 Ω and 40 Ω.
7. If any of the readings are significantly high or significantly low, remove the intermediate
cable from the generator and perform the same measurements as in step 4 on the
generator connector. If the reading are now correct check and or replace the intermediate
cable.refer to Diagram 5.1. If the readings are still incorrect, remove the six phase
generator.
8. Replace the generator per Procedure 7.18. Reconnect the intermediate cable removed in
step 5 to the replacement generator and the lower PCA.
9. Reconnect the red battery lead to terminal M6 of the lower PCA.
10. set the black plastic shield in its mounting position and fasten it with the screws removed in
step 2.
11. Set the right side of the rear cover in it’s mounting position and rotate it clockwise. Ensure
that the cover is fully engaged and fasten it with the screw removed in step 1.

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Diagram 5.1 - Lower PCA
Red
Battery
Connection
Generator
Connector
Load
Resistor
Connections
Cable
Lower
Interconnect

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Procedure 5.2 - Inspecting and Adjusting Belt Tension
Procedure
1. Remove both screws at the rear of the rear cover. Grasp the right side of the rear cover and
rotate it counterclockwise to remove the cover. Grasp the left side of the rear cover and
rotate it clockwise to remove the cover. Refer to procedure 7.1.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.
.
WARNING
If the EFX has been in recent use, the load resistors and mounting bracket may be extremely
hot.
2. Remove the two screws that retain the black plastic shield on the left side of the EFX.
Remove the black plastic shield from the EFX.
3. Place a 20030-108 or equivalent belt gauge on the input belt as shown in Diagram 5.2.
Diagram 5.2 - Input Belt Tension Measurement
Left Side Adjustment Bolt

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4. The belt gauge should read approximately 160 lbs. If the belt tension is significantly high or
low the belt tension may be adjusted using the adjustment bolts shown in Diagram 5.2. To
adjust the belt tension first straighten the locking tabs on both bolts. When adjusting the
tension, turn both bolts equal amounts. When the adjustment is complete the step up pulley
shaft must remain perpendicular to the frame and drive belt. Turning the adjustment bolts
clockwise will increase belt tension, turning the adjustment bolts counter-clockwise will
decrease belt tension.
5. Changing the tension of the input drive belt will also affect the tension of the generator belt.
If the input belt tension has been changed, continue with step 7.
6. Place a 20030-108 or equivalent belt gauge on the generator belt as shown in Diagram 5.3.
Diagram 5.3 - Generator Belt Tension Measurement
7. The belt gauge should approximately 110 lbs. If the generator belt tension is significantly
high or low, it may be adjusted using the adjustment bolt shown in Diagram 5.3. First loosen,
but do not remove the four generator mounting nuts. Thread the adjustment bolt into or out
of the generator to change the belt tension. When the tension is correct, tighten the locking
nut. Tighten and torque the four generator mounting nuts to 200 inch pounds.
8. If either the input pulley belt or the generator belt is being replaced with a new belt, the belt
tension should be set 20 lbs. higher than the previous readings. Therefore a new input
pulley belt should be tensioned to 180 lbs. and a new generator belt should be tensioned to
130 lbs. Over time and use the belts will “relax” and the tensions will be as stated in steps 4
and 7.
9. Reconnect the red battery lead to terminal M6 of the lower PCA.
Generator Adjustment Bolt Generator Mounting Nut

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10. Set the right side of the rear cover in it’s mounting position and rotate it clockwise. Ensure
that the cover is fully engaged and fasten it with the screw removed in step 1. Set the left
side of the rear cover in it’s mounting position and rotate it counterclockwise. Ensure that the
cover is fully engaged and fasten it with the screw removed in step 1

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Procedure 5.3 - Calibrating the Incline Motor
1. Set the incline at its lowest position and remove the lift cover per Procedure 7.2.
1. Remove the four screws that retain the lower front portion of the front cover. Remove the
lower front cover
2. Grasp the center ramp cover and lift it to unsnap it from the ramp. Remove the cover.
3. Remove the two bolts that retain the incline motor yoke assembly in the ramp.
4. Carefully, slide the incline motor yoke out of the ramp and lower the ramp until it is resting
on the frame.
Diagram 5.4 - incline Motor Mounting and Calibration
5. Access the incline A/D reading via the Lift Test portion of the Diagnostic Program, see
Procedure 3.2.
6. With the A/D number displayed set it for a reading of 127 using the CROSSRAMP and
CROSSRAMP keys.
9-1/2”
Center
Ramp
Cover
incline Yoke