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Precor C542i Manual

Precor C542i Manual

Elliptical fitness crosstrainer
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C542i Elliptical Fitness Crosstrainer
C542i 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.
© 2005 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20039-148
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  • Page 1 C542i 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.

  • Page 2: Section One - Things You Should Know

    C542i 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 EFX, facing the display enclosure.
  • Page 3 C542i 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

    C542i 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” allen key, socket wrench mounted...

  • 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 C542i ramps. Use of any other cleaner, may cause degradation of the ramp anodizing and void the ramp warranty.

  • Page 6: Quarterly Maintenance

    C542i Elliptical Fitness Crosstrainer Quarterly Maintenance Remove the rear covers. Check the step up and input belt alignment and tension as in Procedure 5.2. 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

    C542i Elliptical Fitness Crosstrainer Procedure 3.1 - Software Access Codes The C542i 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.

  • Page 8: Procedure 3.2 - Accessing The Diagnostic Program

    Procedure Start pedalling and continue to pedal as you perform step 2. With the PRECOR banner scrolling, press keys RESET,5,1,7,6,5,7,6,1., sequentially. The message HARDWARE VALIDATION will be displayed for a few seconds. The message DISPLAY TEST will be displayed followed by every LED on the display being illuminated.
  • Page 9 C542i 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

    Procedure Start pedalling and continue to pedal as you perform step 2. With the PRECOR banner scrolling, press keys RESET,6,5, sequentially. The message INFORMATION DISPLAY will be displayed for a few seconds. The message ODOMETER will be displayed followed by the total number of strides accumulated.

  • Page 11: Procedure 3.4 - Club Settings

    Procedure 3.4 - Club Settings Start pedalling and continue to pedal as you perform step 2. With the PRECOR banner scrolling, press keys RESET,5,6,5,1,5,6,5, sequentially. The message SET CLUB PARAMETERS will be displayed for a few seconds. The message SELECT LANGUAGE will be displayed followed by the currently selected keys to select the language preference.

  • Page 12: Procedure 3.5 - Documenting Software Problems

    If you isolated the problem to either the PROM, upper PCA, or lower PCA, include the information you recorded with the malfunctioning PROM or PCA when you ship it to Precor. When a problem occurs, record the following information: •...
  • Page 13 Start striding on the EFX or plug the optional external power supply (when available) into the EFX and the AC outlet. At the PRECOR banner, press QUICK START. Select Resistance Level 1 and press ENTER. Operate the EFX for 4–5 minutes. As you operate the EFX, concentrate on the operating sounds made by the unit.

  • Page 14: Procedure 5.1 - Measuring The Resistance Of A Generator

    C542i 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 15 C542i Elliptical Fitness Crosstrainer Replace the generator per procedure 7.17. 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 15...

  • Page 16: Procedure 5.2 - Inspecting And Adjusting Belt Tension

    C542i 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 17 C542i 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 18: Procedure 5.3 - Calibrating The Lift Motor

    C542i 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 19: Procedure 6.1 - Troubleshooting The Lower And Upper Interconnect Cable

    C542i Elliptical Fitness Crosstrainer Procedure 6.1 - Troubleshooting the Lower and Upper Interconnect Cable Typical symptoms associated with a defective interconnect cable is either an error 30 or no power to the upper PCA. This procedure requires that you have a known good upper...
  • Page 20 C542i Elliptical Fitness Crosstrainer 13. Remove the rear cover. Disconnect the lower interconnect cable from the lower PCA and the mid-point connector. Substitute a known good interconnect cable from the lower PCA to the mid-point connector. It is not necessary to route the test interconnect cable through the frame tube, for convenience route it externally.

  • Page 21: Procedure 6.2 - Troubleshooting The Keypad And Upper Pca

    C542i 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 22 C542i Elliptical Fitness Crosstrainer Set the on/off switch in the “on” position. If an Error 5 “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 23: Procedure 6.3 - Upper Display Does Not Illuminate

    C542i 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 24 C542i Elliptical Fitness Crosstrainer Diagram 6.3 - 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 25: Procedure 6.4 - Troubleshooting The Generator

    C542i 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. Lastly, one of the generators six phase output windings is monitored to determine when the unit is in use and when it is idle.
  • Page 26 C542i Elliptical Fitness Crosstrainer Procedure 6.5 - 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 27 C542i 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 28: Procedure 7.1 - Replacing The Display Enclosure Or Upper Pca

    Procedure 7.1 - 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 29 C542i Elliptical Fitness Crosstrainer Diagram 7.1 - Display Housing Front Panel, Rear View Upper PCA J5 Connector Keypad Connector Keypad Position the upper PCA at its mounting location on the display housing front panel (refer to Diagram 7.1). Replace and tighten the upper PCA mounting screws.
  • Page 30 C542i Elliptical Fitness Crosstrainer Procedure 7.2 - 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 31 C542i 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 32 C542i Elliptical Fitness Crosstrainer Procedure 7.3 - Replacing the Upper and/or Lower Interconnect Cables Procedure Note: Before you install a new interconnect cable, ensure that the interconnect cable is defective. Refer to Procedure 6.1. Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 33 C542i Elliptical Fitness Crosstrainer Securely tape one end of the replacement lower interconnect cable to the lower PCA end of the existing lower interconnect cable. Carefully draw the existing lower interconnect cable out of the front of the frame as you carefully feed the replacement cable into the access hole near the lower PCA.
  • Page 34 C542i Elliptical Fitness Crosstrainer Procedure 7.4 - 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 35 C542i 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. Position the crankarm on the input pulley shaft. Thread and hand tighten the 14 mm. bolt into the input pulley shaft.
  • Page 36 C542i Elliptical Fitness Crosstrainer Procedure 7.5 - 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 and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 37 C542i Elliptical Fitness Crosstrainer Procedure 7.6 - 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 38 C542i 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 39 C542i Elliptical Fitness Crosstrainer Procedure 7.7 - 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 and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 40 C542i 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 41 C542i Elliptical Fitness Crosstrainer Procedure 7.8 - 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 and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 42 C542i Elliptical Fitness Crosstrainer Procedure 7.9 Replacing a Wheel Assembly On February 2, 2004 the wheel assembly was modified to a wheel assembly utilizing larger bearings and a larger mounting bolts. If the wheel being replaced has large (5/16-18) mounting bolts, skip to step 7. If the wheel being replaced has a small (8-32) mounting screw, continue with step 2.
  • Page 43 C542i Elliptical Fitness Crosstrainer Remove the two wheel axle bolts from the wheel. Discard the bolts and the wheel. Replacement wheel mounting bolts are furnished with the replacement wheel. Install the replacement wheel assembly in the wheel cover. Install and hand tighten the two wheel axle bolts.
  • Page 44 C542i Elliptical Fitness Crosstrainer Procedure 7.10 - 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 45 C542i Elliptical Fitness Crosstrainer Procedure 7.11 - Replacing a Stairarm Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 46 C542i Elliptical Fitness Crosstrainer Procedure 7.12 - Replacing a Ramp Assembly Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 47 C542i Elliptical Fitness Crosstrainer Diagram 7.9 - Upper Ramp Mounting Upper Ramp Mounting Bolts Rotate both stairarms forward and place them on the ramp tracks. Replace the left and right rear covers per Procedure 7.14 and check unit operation as described in Section Four.
  • Page 48 C542i Elliptical Fitness Crosstrainer Procedure 7.13 - Replacing a Handlebar Slide the lower handle bar boot up the handlebar to expose the lower handlebar mounting bolts. Remove both of the lower handlebar mounting bolts. See Diagram 7.10. Diagram 7.10 - Lower Handlebar Mounting...
  • Page 49 C542i Elliptical Fitness Crosstrainer Procedure 7.14 - Replacing a Main Column Procedure Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA. Attach the anti-static wrist strap to your arm, then connect the ground lead of the wrist strap to the EFX frame.
  • Page 50 C542i Elliptical Fitness Crosstrainer Remove both handlebars per Procedure 7.13. Remove the left and right frame tube per Procedure 7.21. 10. Remove the two bolts and washers that fasten the bottom of the main column to the frame base. See Diagram 7.11. Remove the main column.
  • Page 51 C542i Elliptical Fitness Crosstrainer Procedure 7.15 - 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 7.12).
  • Page 52 C542i Elliptical Fitness Crosstrainer Diagram 7.13 - 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 53: Load Resistor

    C542i Elliptical Fitness Crosstrainer Procedure 7.16 - 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. Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower PCA.
  • Page 54 C542i 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 55: Procedure 7.17 - Replacing A Generator

    C542i Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing a Generator WWARNING 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 56 C542i Elliptical Fitness Crosstrainer Diagram 7.16 - 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 57: Procedure 7.18 - Replacing A Battery

    C542i Elliptical Fitness Crosstrainer Procedure 7.18 - 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. Refer to Diagram 7.17.
  • Page 58 C542i Elliptical Fitness Crosstrainer Diagram 7.18 - Battery Bracket, Front Retaining Bracket Side Bracket Front Retaining Bracket Mounting Remove the nut that fastens the front battery retaining bracket. Refer to Diagram 7.18. Carefully, slide the battery out of the battery bracket.
  • Page 59 C542i Elliptical Fitness Crosstrainer Procedure 7.19 - 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 7.17.
  • Page 60 C542i Elliptical Fitness Crosstrainer 11. Replace the red battery lead removed in step 1 and check unit operation as described in Section Four. Page 60...

  • Page 61: Procedure 7.20 - Replacing A Lift Motor

    C542i Elliptical Fitness Crosstrainer Procedure 7.20 - 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 62 C542i Elliptical Fitness Crosstrainer Procedure 7.21 - Replacing a Frame Tube Procedure Remove the two screws that fasten the cover near the middle of the main column. Remove the cover. Remove the four bolts and washers that fasten the lower end of the frame tube to the frame base.

  • Page 63: Mounting Bolt

    C542i Elliptical Fitness Crosstrainer Procedure 7.22 - Replacing a Ramp Mounting Bracket Warning: Care must be taken when work is being performed in the area of the stairarms. Pinch points exist between the stairarm and ramp and between the stairarm and crankarm, when the rear covers are removed.
  • Page 64 C542i Elliptical Fitness Crosstrainer Set the replace mounting bracket at its mounting position on the frame. Fasten the ramp mounting bracket with the hardware removed in step 6, slide the wave washer onto the bolt and then the shim. Torque the bolts to 40 ft./lbs.
  • Page 65 C542i Elliptical Fitness Crosstrainer Procedure 7.23 - 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 66 C542i Elliptical Fitness Crosstrainer Wiring Diagram 8.1 - C542i 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 66...
  • Page 67 C542i Elliptical Fitness Crosstrainer Block Diagram 8.2 - C542i Self Powered Page 67...

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