Precor C546i User manual

C546i Self Powered Elliptical Fitness Crosstrainer
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C546i Self Powered 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.
© 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 ramp operating system has a battery monitoring system. If the battery voltage falls
below 11 Vdc when ramp movement is initiated or the battery voltage falls below 10 Vdc
after ramp movement has been initiated, ramp movement will be stopped and the message
“NO RAMP LOW VOLTAGE” will be displayed. Ramp motion will not be enabled until such
time as the battery voltage exceeds the above limits.
• 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 three 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.

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• 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.
• 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.

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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, see 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 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. See 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
Diagram 3.1 - C546i Display Panel
Key 1
Reset Key 4 Key 7

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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. With the PRECOR banner displayed, 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 brake 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 lift test.
9. The message LIFT TEST will be displayed followed by the ramp level and A/D (analog to
digital) reading. The A/D is the number the system use to track the lift position. The A/D
number will be used in the lift calibration portion of this service manual. (Procedure 5.3).

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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 banner displayed, 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. The total number of strides can be converted to miles by dividing by 2241 or
to kilometers by dividing by 1392.5. 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. When a new error is logged, each
existing error is pushed down one position and the error in position 10, if any, is lost. 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.