Precor C546i Service Manual
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Precor C546i Service Manual

Precor C546i Service Manual

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C546i Self Powered Elliptical Fitness Crosstrainer
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.
If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product;
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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  • Page 1 (version 2, serial codes AA32, AAAJ, ADEE) Warning: This service manual is for use by Precor trained service providers only. If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product; Call your dealer for service.
  • Page 2 C546i Self Powered Elliptical Fitness Crosstrainer © 2004 Precor Incorporated Unauthorized Reproduction and Distribution Prohibited By Law Page 2...

  • Page 3: Section One - Things You Should Know

    C546i Self Powered Elliptical Fitness Crosstrainer 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 •...

  • Page 4: General Information

    • 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...

  • Page 5: Section Two - Preventive Maintenance

    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.

  • Page 6: Quarterly Maintenance

    C546i Self Powered Elliptical Fitness Crosstrainer Quarterly Maintenance Remove the rear covers. Check the step up and input belt alignment and tension as in Procedure 5.3. Replace the rear cover. On-Site Preventive Maintenance (Service Technician) When you are called to service a EFX, perform these preventive maintenance activities: •...

  • Page 7: Procedure 3.1 - Software Access Codes

    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...

  • Page 8: Procedure 3.2 - Accessing The Diagnostic Program

    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.
  • Page 9 C546i Self Powered Elliptical Fitness Crosstrainer 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.

  • Page 10: Procedure 3.3 - Displaying The Odometer

    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. The message SOFTWARE VERSION will be displayed followed by the upper software part number UPPER APP XXXX-XXX.

  • Page 11: Procedure 3.4 - Club Settings

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 3.4 - Club Settings Start pedalling and continue to pedal as you perform step 2. Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially. The message SET CLUB PARAMETERS will be displayed for a few seconds.

  • Page 12: Procedure 3.5 - Documenting Software Problems

    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.

  • Page 13: Procedure 3.6 - Software Uploading Procedure

    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”...
  • Page 14 Resistance Level 20. Operate the EFX for another 2–3 minutes. 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.

  • Page 15: Procedure 5.1 - Measuring The Resistance Of A Generator

    C546i Self Powered Elliptical Fitness Crosstrainer 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 Remove the screw at the right rear of the rear cover.
  • Page 16 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 5.1 - Lower PCA Lower Interconnect Cable Battery Connection Load Resistor Generator Connections Connector Page 16...

  • Page 17: Procedure 5.2 - Inspecting And Adjusting Belt Tension

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 5.2 - Inspecting and Adjusting Belt Tension Procedure 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.
  • Page 18 C546i Self Powered Elliptical Fitness Crosstrainer 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.
  • Page 19 C546i Self Powered Elliptical Fitness Crosstrainer 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.

  • Page 20: Procedure 5.3 - Calibrating The Incline Motor

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 5.3 - Calibrating the Incline Motor Set the incline at its lowest position and remove the lift cover per Procedure 7.2. Remove the four screws that retain the lower front portion of the front cover. Remove the lower front cover Grasp the center ramp cover and lift it to unsnap it from the ramp.
  • Page 21 C546i Self Powered Elliptical Fitness Crosstrainer Rotate the incline motor yoke on the incline motor drive screw until the measurement between the top of the incline nut and the end of the incline motor drive screw is 9-1/2 inches. See Diagram 5.4. While rotating the incline motor yoke, do not allow the incline motor drive screw to rotate.

  • Page 22: Procedure 6.1 - Troubleshooting The Lower And Upper Interconnect Cables

    Procedure 6.1 - Troubleshooting the Lower and Upper Interconnect Cables Anti-static kits can be ordered from Precor (part number 20024-101). Troubleshooting the Upper Interconnect Cable Remove the five screws from the rear of the upper display housing. Remove the display housing front panel from the display housing.
  • Page 23 C546i Self Powered Elliptical Fitness Crosstrainer Troubleshooting the Lower Interconnect Cable Remove the right side rear cover as described in procedure 7.1. Disconnect the lower interconnect cable from the mid-point connector and the lower PCA. Refer to Diagram 5.1. External of the frame, connect a replacement lower interconnect cable to the mid-point connector and the lower PCA.

  • Page 24: Procedure 6.2 - Troubleshooting The Keypad And Upper Pca

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 6.2 - Troubleshooting the Keypad and Upper PCA If the function keys on the electronic console are unresponsive, the problem may be either the upper PCA or keypad. The keys on this unit are touch sensitive keys. It is necessary to use the keypad diagnostics to troubleshoot the key functions.
  • Page 25 C546i Self Powered Elliptical Fitness Crosstrainer If a “stuck key” message is immediately displayed when the EFX is powered up, replace the upper PCA. If a “stuck key” message is not displayed when the EFX is powered up, replace the display housing front panel.

  • Page 26: Procedure 6.3 - Upper Display Does Not Illuminate

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 6.3 - Upper Display does not Illuminate Because this is self powered unit, the display will not illuminate until it is used or the optional external power supply is equipped. If the optional external power supply is equipped, the display should be constantly illuminated.
  • Page 27 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 6.4 - Partial View of Lower PCA DGND, TP4 PROM +5D, TP13 DS1 LED J2 Connector 10. Troubleshoot the upper to lower PCA interconnect cables per Procedure 6.1. 11. If the upper to lower interconnect cables are found to be good, replace the upper PCA.

  • Page 28: Procedure 6.4 - Troubleshooting The Generator

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 6.4 - Troubleshooting the Generator 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.

  • Page 29: Procedure 6.5 - Troubleshooting Hand Held Heart Rate

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 6.5 - Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system, that is, it can accept a heart rate signal from either the hand held heart rate contacts on the unit’s handlebar or from a Polar heart rate chest strap transmitter.
  • Page 30 12. Remove the temporary jumper from J14 of the heart rate PCA. Re-locate all potential sources of radiation. Pedal the C546i to power it on and repeat the procedure in step 6. 13. Access the diagnostic program (Procedure 3.2). Advance to the heart rate display portion of the diagnostic program.
  • Page 31 C546i Self Powered Elliptical Fitness Crosstrainer 15. Refer to Diagram 6.5 for the following measurements. With an ohmmeter measure between the “lower right contact” pin on the J1 connector and the lower right hand held heart rate contact on the handlebar. The reading should be 1 Ω or less. Measure between the “upper right contact”...

  • Page 32: Procedure 6.6 - Troubleshooting The Incline System

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 6.6 - Troubleshooting the Incline System The incline motor is a 12 Vdc motor with an internally driven 1 KΩ potentiometer used to track ramp position. Because the incline motor is a DC motor, incline motor direction is controlled by the polarity of the DC voltage applied to the incline motor.
  • Page 33 C546i Self Powered Elliptical Fitness Crosstrainer Remove both front covers. Enter the diagnostic program, if necessary, per Procedure 3.2. Using the diagnostic program allows to test the incline system without continuously pedalling the unit. Connect a DC volt meter to the incline motor cable as follows: voltmeter common lead to terminal 2 (brown wire) and voltmeter “hot”...

  • Page 34: Procedure 7.1 - Replacing The Rear Covers

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.1 - Replacing the Rear Covers WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Replacing the Left and/or Right Side Rear Cover Remove the two screws at the rear of the rear cover.
  • Page 35 C546i Self Powered Elliptical Fitness Crosstrainer 11. Remove the top section of the cover as described above. 12. Remove the nut retaining the external power supply input jack. Refer to Diagram 7.1 13. Remove the external power supply input jack from the cover.
  • Page 36 C546i Self Powered Elliptical Fitness Crosstrainer 23. Remove the lower PCA and bracket and carefully support it away from the front section of the cover. 24. Remove the small cover at the front portion of the cover section by sliding it forward and off of the front section of the cover.

  • Page 37: Procedure 7.2 - Replacing The Lift Covers

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.2 - Replacing the Lift Covers Replacing the Upper Lift Cover Section The large upper section of the front cover is fastened to the lower cover sections. However, there are two plastic clips, one on each side of the upper lift cover, that retain the upper portion of the lift cover to the uprights.
  • Page 38 C546i Self Powered Elliptical Fitness Crosstrainer Replacing the Lower Front Lift Cover Section Remove the upper lift cover section as described above. Remove the four screws that fasten the front cover section to the rear cover section. Remove the front cover section from the EFX.
  • Page 39 C546i Self Powered Elliptical Fitness Crosstrainer 17. Set the incline motor in its mounting position and slide the clevis pin into the incline motor’s lower mount. Fasten the clevis pin with the hitch pin. 18. Replace the front and upper cover sections as described above.

  • Page 40: Procedure 7.3 - Replacing The Display Enclosure Or Upper Pca

    Procedure 7.3 - Replacing the Display Enclosure or Upper PCA Anti-static kits (part number 20024-101) can be ordered from Precor. The keyboard is part of the display housing front panel. If the keyboard is not functioning properly, replace the display housing front panel.
  • Page 41 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.6 - Display Housing Front Panel, Rear View Upper PCA Connector Keypad Cable Position the upper PCA at its mounting location on the display housing front panel (refer to Diagram 7.6). Replace and tighten the upper PCA mounting screws.

  • Page 42: Procedure 7.4 - Replacing The Lower Pca

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.4 - Replacing the Lower PCA Removing the Lower PCA Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 43 M1 or M2 terminal. Remove the ground lead of the wrist strap from the EFX frame, then remove the wrist strap from your arm. Re-install the rear cover, then check the operation of the C546i as described in Section Four. Page 43...

  • Page 44: Procedure 7.5 - Replacing The Upper Or Lower Interconnect Cables

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.5 - Replacing the Upper or Lower Interconnect Cables Before you install a new interconnect cable, ensure that the interconnect cable is defective as described in Procedure 6.1. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 45 C546i Self Powered Elliptical Fitness Crosstrainer 12. Carefully pull the old interconnect cable out of the mid-point access hole while feeding the new interconnect cable into the unit. When the new cable is fully into the unit, remove the tape and discard the old interconnect cable. Connect the lower interconnect cable to the mid-point connector and push them into the access hole.

  • Page 46: Procedure 7.6 - Replacing A Crankarm Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.6 - Replacing a Crankarm Assembly Removing a Crankarm Assembly WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. It is only necessary to remove the right or left side of the rear cover to access the crankarm being replaced.
  • Page 47 C546i Self Powered Elliptical Fitness Crosstrainer Replacing a Crank Arm Assembly Clean the crankarm mounting bolt threads and the input pulley shaft threads with an alcohol swab. Allow them to dry and apply blue loctite to the crankarm mounting bolt threads.

  • Page 48: Procedure 7.7 - Replacing A Incline Motor

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.7 - Replacing a Incline Motor Remove upper and front cover sections per Procedure 7.1. Remove the hitch pin from the clevis at the lower incline motor mount. Remove the clevis pin from the lower incline motor mount.
  • Page 49 C546i Self Powered Elliptical Fitness Crosstrainer Connect the replacement incline motor’s cable to the intermediate cable. 10. Mount the incline motor to the EFX frame with the clevis and hitch pins removed in step 2. 11. Calibrate the incline motor per Procedure 5.3.

  • Page 50: Procedure 7.8 - Replacing The Input Pulley Belt

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.8 - Replacing the Input Pulley Belt WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.

  • Page 51: Procedure 7.9 - Replacing The Generator Pulley Belt

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.9 - Replacing the Generator Pulley Belt WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.
  • Page 52 C546i Self Powered Elliptical Fitness Crosstrainer 18. Check the operation of the EFX as described in Section Four. Page 52...

  • Page 53: Procedure 7.10 - Replacing The Input Pulley Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.10 - Replacing the Input Pulley Assembly WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.
  • Page 54 C546i Self Powered Elliptical Fitness Crosstrainer Replace the crankarms per Procedure 7.7. The crankarms must be parallel to the frame uprights. Refer to Diagram 7.10. If necessary loosen the four drive unit mounting bolts, align the drive unit and torque the drive unit mounting bolts to 400 inch pounds.

  • Page 55: Procedure 7.11 - Replacing The Step-Up Pulley Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.11 - Replacing the Step-Up Pulley Assembly WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the left and right side rear covers per Procedure 7.1.

  • Page 56: Procedure 7.12 - Replacing A Stairarm Wheel

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.12 - Replacing a Stairarm Wheel Procedure WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the lift cover per Procedure 7.2.
  • Page 57 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.12 - Stairarm Wheel Stairarm Mounting Wheel Screw Slide the replacement wheel onto the stairarm axle. Fasten the wheel with the hardware removed in step 6. Apply blue loctite to the wheel mounting screws and torque them to 180 inch pounds.

  • Page 58: Procedure 7.13 - Replacing A Stairarm Pedal

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.13 - Replacing a Stairarm Pedal Loosen and remove the four screws that fasten the stairarm pedal onto the stairarm. Refer to Diagram 7.13. Remove the stairarm pedal from the stairarm. Set the replacement stairarm pedal at it’s mounting position on the stairarm.

  • Page 59: Procedure 7.14 - Replacing A Stairarm

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.14 - Replacing a Stairarm Remove the left and right side rear cover. Remove the cover from the rear of the stairarm. The cover’s retaining screw is on the inside and must be accessed from the opposite side of the EFX. Carefully, rotate the stairarm to a position just forward of vertical to gain access to the cover’s retaining screw.
  • Page 60 C546i Self Powered Elliptical Fitness Crosstrainer Remove both wheels and slide them onto the replacement stairarm’s axle. Apply blue loctite to the wheel mounting screws and torque the wheel mounting screws to 180 inch pounds. Slide the stairarm onto the crankarm and set the stairarm in its ramp track. Fasten the stairarm to the crankarm with the retaining ring removed in step 7.

  • Page 61: Procedure 7.15 - Replacing A Ramp Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.15 - Replacing a Ramp Assembly Procedure Raise the incline to its highest position. Remove both stairarms per Procedure 7.14. Remove the four bolts that fasten the ramp pivot to the ramp. Refer to Diagram 7.15.
  • Page 62 C546i Self Powered Elliptical Fitness Crosstrainer Remove the ramp from the EFX. Remove the two screws that fasten the rear ramp end cap to the ramp. Set the rear ramp end cap at its mounting position on the replacement ramp and fasten with the screws removed above.

  • Page 63: Procedure 7.16 - Replacing A Handlebar

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.16 - Replacing a Handlebar Remove the screw in the handlebar clamp that fastens the handlebar being replaced. Refer to Diagram 7.17 Diagram 7.17 - Upper Handlebar Mounting Using a large adjustable wrench, remove the special handlebar attachment bolt from the lower end of the handlebar(s) being removed.
  • Page 64 C546i Self Powered Elliptical Fitness Crosstrainer The hand held heart rate wiring is inside of the handlebar and care must be taken to not damage the wiring when the handlebar is removed. Carefully, slide the upper end of the handlebar out of the handlebar clamp. Disconnect the hand held heart rate wiring at the connector at the upper end of the handlebar.

  • Page 65: Procedure 7.17 - Replacing A Generator

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing a Generator WARNING When the unit is used, stairarms are in motion or the generator is rotated by any means, the generator will produce potentially hazardous voltages even when the battery is disconnected.
  • Page 66 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.20 - Generator Bearing Clamp Bearing Clamp Bearing Clamp Mounting Screw 10. Replace and tighten the three generator mounting screws removed in step 9. Set the bearing clamp in its mounting position, replace and tighten the two bearing clamp mounting screws removed in step 9.

  • Page 67: Procedure 7.19 - Replacing A Battery

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.19 - Replacing a Battery Remove the lift cover per Procedure 7.2. Remove the four screws that retain the lower front cover section, remove the lower front cover section and set it aside.
  • Page 68 C546i Self Powered Elliptical Fitness Crosstrainer Set the battery in its mounting position. Set the battery bracket in its mounting position and fasten it with the screws removed in step 8. Set the incline motor in its mounting position and slide the clevis pin into the incline motor’s lower mount.

  • Page 69: Procedure 7.20 - Replacing An External Power Input Jack

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.20 - Replacing an External Power Input Jack Remove the left and right side rear covers sections per Procedure 7.1. Disconnect the J4 connector from the lower PCA. Diagram 7.23 - Power Input Jack Mounting...

  • Page 70: Procedure 7.21 - Replacing The Prom

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.21 - Replacing the PROM Anti-static kits (part number 20024-101) can be ordered from Precor. The PROM and the associated printed circuit assembly (PCA) are static sensitive. Anti- static devices must be used and all anti-static precautions must be followed during this procedure.

  • Page 71: Wiring Diagram 8.1 - C546I Self Powered

    C546i Self Powered Elliptical Fitness Crosstrainer Wiring Diagram 8.1 - C546i Self Powered Jack Battery J1-5 J1-6 J1-7 J3-6 J3-5 J3-4 J3-2 J3-3 Lift Motor Intermediate Connector Page 71...

  • Page 72: Block Diagram 8.2 - C546I Self Powered

    C546i Self Powered Elliptical Fitness Crosstrainer Block Diagram 8.2 - C546i Self Powered Page 72...

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