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
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.
© 2004 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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Summary of Contents for Precor C546i

  • Page 1 C546i Self Powered Elliptical Fitness Crosstrainer 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: 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.
  • Page 3 C546i Self Powered Elliptical Fitness Crosstrainer • 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.

  • Page 4: General Information

    C546i Self Powered Elliptical Fitness Crosstrainer 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”...

  • 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

    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.

  • 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 Remove power from the EFX before you measure magnet resistance. Procedure Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 16 C546i Self Powered Elliptical Fitness Crosstrainer Replace the generator per Procedure 7.18. Reconnect the intermediate cable removed in step 5 to the replacement generator and the lower PCA. Reconnect the red battery lead to terminal M6 of the lower PCA.

  • 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 the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. If you are only inspecting the generator belt tension, skip to step 7.
  • Page 18 C546i Self Powered Elliptical Fitness Crosstrainer 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.
  • Page 19 C546i Self Powered Elliptical Fitness Crosstrainer 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.

  • Page 20: Procedure 5.3 - Calibrating The Lift Motor

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 5.3 - Calibrating the Lift Motor Remove both front covers. Remove the four screws that fasten the lift motor yoke into the ramp. Carefully, slide the lift motor yoke out of the ramp and lower the ramp until it is resting on the frame.

  • Page 21: Procedure 6.1 - Troubleshooting The Lower And Upper Interconnect Cables

    C546i Self Powered Elliptical Fitness Crosstrainer 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 WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 22 Procedure 4. 20. Replace the lower PCA shield, rear cover (Procedure 7.1) and the main column cover. If the unit still does function correctly, contact Precor Technical Support. Page 22...

  • Page 23: 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 24 C546i Self Powered Elliptical Fitness Crosstrainer If a “key depressed” message is immediately displayed when the EFX is powered up, replace the upper PCA. If a “key depressed” message is not displayed when the EFX is powered up, replace the display housing front panel.

  • Page 25: 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 26 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 6.4 - Partial View of Lower PCA DGND, TP14 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 27: 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 28: 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 29 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 30 22. Temporarily, install a spare jumper on J14 of the heart rate PCA (hand held priority). Pedal the C546i to power it on and repeat the procedure in step 6. 23. If the hand held signal is now being accept, something in the near vicinity is radiating RF energy that is being received by the chest strap portion of the heart rate PCA.

  • Page 31: Procedure 6.6 - Troubleshooting The Lift Motor

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 6.6 - Troubleshooting the LIft Motor The lift motor is a 12 Vdc motor with an internally driven 1 KΩ potentiometer used to track ramp position. Because the lift motor is a DC motor, lift motor direction is controlled by the polarity of the DC voltage applied to the lift motor.
  • Page 32 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 lift system without continuously pedalling the unit. Connect a DC volt meter to the lift motor cable as follows: voltmeter common lead to terminal 2 (brown wire) and voltmeter “hot”...

  • Page 33: Procedure 7.1 - Replacing The Mid-Point Cover

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.1 - Replacing the Mid-Point Cover WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 20. Remove two screws that fasten the upper mid-point cover. Remove two screws that fasten the lower mid-point cover.

  • Page 34: Procedure 7.2 - Replacing The Display Enclosure Or Upper Pca

    Procedure 7.2 - 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 35 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.2 - 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 7.2). Replace and tighten the upper PCA mounting screws.

  • Page 36: Procedure 7.3 - Replacing The Lower Pca

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.3 - 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 37 C546i Self Powered Elliptical Fitness Crosstrainer Replacing the Lower PCA Position the replacement lower PCA at its mounting position and fasten the lower PCA with the four screws removed in step 5. Reconnect the lower PCA cables and wiring as follows. Connect the interconnect cable to connector J2.
  • Page 38 C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.4 - Replacing the Upper and/or Lower Interconnect Cables Before you install a new interconnect cable, ensure that the interconnect cable is defective as described in Procedure 6.1. Procedure Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 39 C546i Self Powered Elliptical Fitness Crosstrainer Replacing the Lower Interconnect Cable 11. Remove the rear cover per Procedure 7.19. Disconnect the interconnect cable from the lower PCA (connector J2). See Diagram 7.3. 12. The upper and lower interconnect cables are connected at the mid-point of the main column.

  • Page 40: Procedure 7.5 - Replacing A Crankarm Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.5 - 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 41 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 42: Procedure 7.6 - Replacing The Input Pulley Belt

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.6 - 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 rear cover per Procedure 7.19.

  • Page 43: Procedure 7.7 - Replacing The Generator Pulley Belt

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.7 - 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 rear cover and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 44 C546i Self Powered Elliptical Fitness Crosstrainer 17. Tension both belts per Procedure 5.2. Note the differences between tensioning a new belt and a existing (used) belt. 18. Replace the red battery lead removed in step 1 and check unit operation as described in Section Four.

  • Page 45: Procedure 7.8 - Replacing The Input Pulley Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.8 - 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 rear cover per Procedure 7.19.
  • Page 46 C546i Self Powered Elliptical Fitness Crosstrainer Remove the input pulley assembly. Slide input pulley belt off of the input pulley assembly. Hold the replacement input pulley assembly at it’s mounting position and slide the input belt over and past the pillow block bearing and onto the input pulley assembly.

  • Page 47: Procedure 7.9 - Replacing The Step-Up Pulley Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.9 - 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 rear cover per Procedure 7.19.

  • Page 48: Procedure 7.10 - Replacing A Wheel Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.10 - Replacing a Wheel Assembly Procedure Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. On February 2, 2004 the wheel assembly was modified to a wheel assembly utilizing larger bearings and a larger mounting bolts.
  • Page 49 C546i Self Powered Elliptical Fitness Crosstrainer Plug the power cord into the wall outlet, set the on/off switch in the “on” position and thoroughly test the operation of the wheel assemblies. Remove the two wheel axle bolts from the wheel. Discard the bolts and the wheel.

  • Page 50: Procedure 7.11 - Replacing A Stairarm Pedal

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.11 - Replacing a Stairarm Pedal Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm. Remove the stairarm pedal from the stairarm. Set the replacement stairarm pedal at it’s mounting position on the stairarm.

  • Page 51: Procedure 7.12 - Replacing A Stairarm

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.12 - Replacing a Stairarm Remove the rear cover per Procedure 7.1. Remove the retaining clip that fastens the stairarm pivot block to the crankarm. Slide the stairarm off of the crankarm. Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm.

  • Page 52: Procedure 7.13 - Replacing A Ramp Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.13 - Replacing a Ramp Assembly Procedure Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. Rotate both stairarms to the rear of the unit.

  • Page 53: Procedure 7.14 - Replacing A Handlebar

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.14 - Replacing a Handlebar Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. Loosen the screws that fasten the upper end of the handrail into the upper handrail clamp.

  • Page 54: Procedure 7.15 - Replacing The Upper Main Column

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.15 - Replacing the Upper Main Column WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Remove the mid-point cover per Procedure 7.1.
  • Page 55 C546i Self Powered Elliptical Fitness Crosstrainer Feed the upper interconnect cable into the replacement upper main column and fasten the display housing to the replacement upper main column with the screws removed in step 7. Draw the upper interconnect cable out of the access hole at the bottom of the upper main column.

  • Page 56: Procedure 7.16 - Replace The Rear Cover

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.16 - Replace the Rear Cover The rear cover is a four piece cover; front, top, left and right sections. If the front cover section is being removed, the frame cover must also be removed (See Diagram 7.11).
  • Page 57 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.12 - Top Cover Section (with right & left cover sections removed) Top Cover Mounting Section Screw Front Cover Frame Section Upright If all four cover sections have been removed, first replace the frame cover and front cover section, then the top cover section and then the left and right cover sections as described below.

  • Page 58: Procedure 7.17 - Replacing A Load Resistor

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing a Load Resistor Warning When the EFX is operated the load resistors get very hot. Be sure to allow the load resistors enough time to cool before continuing with this procedure.
  • Page 59 C546i Self Powered Elliptical Fitness Crosstrainer frame upright with the screws removed in step 2. Route the load resistor wires into the slots at the top of the frame upright. This will keep the wires away from all moving parts, such as the stairarms.

  • Page 60: Procedure 7.18 - Replacing A Generator

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.18 - 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 61 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.15 - 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 62: Procedure 7.19 - Replacing A Battery

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.19 - Replacing a Battery Remove the entire rear cover, including the front section of the cover. Disconnect the red battery lead from terminal M6 of the lower PCA and the black battery lead from M7 of the lower PCA of the lower PCA.
  • Page 63 C546i Self Powered Elliptical Fitness Crosstrainer Diagram 7.17 - Battery Bracket, Front Retaining Bracket Side Bracket Front Retaining Bracket Mounting Remove the nut fastens the front battery retaining bracket. Refer to Diagram 7.17. Carefully, slide the battery out of the battery bracket.

  • Page 64: Procedure 7.20 - Replacing A Power Input Jack Assembly

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.20 - Replacing a Power Input Jack Assembly Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. Disconnect the J4 connector from the lower PCA. See Diagram 7.16.

  • Page 65: Procedure 7.21 - Replacing A Lift Motor

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.21 - Replacing a Lift Motor Remove the left rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. Remove both front covers. Carefully, extract the lift motor cable from the frame access hole and disconnect the lift motor cable from the lift intermediate cable.

  • Page 66: Procedure 7.22 - Replacing The Prom

    C546i Self Powered Elliptical Fitness Crosstrainer Procedure 7.22 - 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 67: 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 67...

  • Page 68: Block Diagram 8.2 - C546I Self Powered

    C546i Self Powered Elliptical Fitness Crosstrainer Block Diagram 8.2 - C546i Self Powered Page 68...

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