Precor C546 Service Manual
  1. Manuals
  2. Brands
  3. Precor Manuals
  4. Elliptical Trainer
  5. C546
  6. Service manual
Precor C546 Service Manual

Precor C546 Service Manual

Precor c546 elliptical fitness crosstrainer
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
C546 Elliptical Fitness Crosstrainerl
C546 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.
© 2003 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
Page 1

Advertisement

Table of Contents
loading

Related Manuals for Precor C546

Summary of Contents for Precor C546

  • Page 1 C546 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

    When servicing a C546 it is critical that you are aware of which version of C546 you are servicing. The differences in the versions may greatly impact service requirements and procedures. For convenience, the versions detailed below will be referred to as version 1, version 2 or version 3 in the reminder of this service manual.
  • Page 3 C546 Elliptical Fitness Crosstrainerl • 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.

  • Page 4: General Information

    J4 terminal 4 J4 terminal 2 J4 terminal 5 J4 terminal 3 J4 terminal 6 For the latest exploded view, part number and part pricing information, visit the Precor dealer website at “www.precor.com/Dealer. Tools Required Multimeter Allen wrench set Anti-static kit Screwdriver set 4”...

  • Page 5: Section Two - Preventive Maintenance

    “Simple Green” is the only cleaning solution that has been tested and approved for use on the C546 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.

  • Page 6: Quarterly Maintenance

    C546 Elliptical Fitness Crosstrainer Quarterly Maintenance Remove front and rear covers. Clean and lubricate the lift motor drive screw with bearing grease. Check the step up and input belt tension as in Procedure 5.3. Replace both covers. 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

    C546 Elliptical Fitness Crosstrainerl Procedure 3.1 - Software Access Codes The C546 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 C546 Elliptical Fitness Crosstrainer Procedure 3.2 - Accessing the Diagnostic Program (version The EFX diagnostic software cycles through the following tests: • LED Diagnostics • Power Bits • Lift Calibration Number • Heart Rate • Keypad Test Procedure Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker.
  • Page 9 C546 Elliptical Fitness Crosstrainerl Diagram 3.1 - C546 Display Key #7 Key #1 Press ENTER, then release. With HArt displayed in the right display window, a heart rate will be displayed when a chest strap or test transmitter is used and the optional heart rate receiver has been installed in the EFX.
  • Page 10 C546 Elliptical Fitness Crosstrainer 11. If the left display window column illuminates appropriately as each key is pressed... THEN... OTHERWISE... The keypad test passed successfully; Troubleshoot per Procedure 6.2 or 6.3 continue with the next step. 12. End the keypad test by pressing the CROSSRAMP...
  • Page 11 C546 Elliptical Fitness Crosstrainerl Procedure 3.3 - Accessing the Diagnostic Program (version 2,3) The EFX diagnostic software cycles through the following tests: • Display Test • Keyboard Test • Heart Rate • Lift Calibration • Brake Test Procedure Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker.
  • Page 12 C546 Elliptical Fitness Crosstrainer Diagram 3.1 - C546 Display Key #1 Key #7 12. The message LIFT TEST will be displayed. 13. The display will read INCLINE followed by the incline setting and A/D followed by the analog to digital lift number (lift calibration number). When the lift is operated, the incline position should change and the A/D number should track the incline position.
  • Page 13 Procedure Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker. With the PRECOR EFX 546 banner scrolling, press keys RESET,6,5, sequentially until the message EFX 546 ODOMETER scrolls across the display window.
  • Page 14 C546 Elliptical Fitness Crosstrainer Press ENTER, the software version and part number of the PROM will be displayed. Note: If you cannot determine the software version number in this manner, look at the PROM mounted on the upper PCA. A label on the PROM indicates the software version number.
  • Page 15 Procedure Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker. With the PRECOR EFX 546 banner scrolling, press keys RESET,6,5, sequentially. The message ODOMETER will be displayed. The display will then read XXXXXXXX STRIDES. Where XXXXXXX is the total number of strides accumulated on the EFX.
  • Page 16 C546 Elliptical Fitness Crosstrainer Procedure 3.6 - Club Settings (version 1) Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially. The maximum workout time will be displayed. The maximum workout may be selected with keys. Press ENTER to continue. either of the The maximum workout time is displayed on the left display window.
  • Page 17 C546 Elliptical Fitness Crosstrainerl Procedure 3.7 - Club Settings (version 2,3) Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially The message SELECT LANGUAGE will be displayed. Use the , keys to select the language to be displayed. When the desired language has been selected, press the ENTER key to continue.
  • Page 18 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 19 Procedure Plug the power cord into the wall outlet and set the on/off switch in the “on” position. When the PRECOR EFX 546..WORK OUT SMARTER banner scrolling, press QUICK START. If the ramp is not currently at the mid-point, the ramp will automatically move to the mid- point.
  • Page 20 C546 Elliptical Fitness Crosstrainer 14. If the ramp system of the EFX 546 does not operate properly, troubleshoot per Procedure 6.5. 15. Turn off the EFX with the circuit breaker, then unplug the power cord from the wall outlet. Page 20...

  • Page 21: Procedure 5.1 - Measuring The Resistance Of An Eddy Current Magnet

    C546 Elliptical Fitness Crosstrainerl Procedure 5.1 - Measuring the Resistance of an Eddy Current Magnet Caution Remove power from the EFX before you measure magnet resistance. Procedure Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet.
  • Page 22 C546 Elliptical Fitness Crosstrainer Procedure 5.2 - Calibrating the Lift Motor (version 1,2) In order to correctly calibrate the lift the unit’s software version must be known. If the unit’s software version is not known, access the software version per Procedure 3.3.
  • Page 23 C546 Elliptical Fitness Crosstrainerl If the unit is equipped with software version 1.13 or less, continue with step 7. If the software version is 1.14 or greater, skip to step 10. Operate the CROSSRAMP or CROSSRAMP keys as required to set the lift calibration number to 200.
  • Page 24 C546 Elliptical Fitness Crosstrainer Procedure 5.3 - Calibrating the Lift Motor (version 3) In order to calibrate the lift motor, it is necessary to disconnect the lift motor from the ramp assembly. Set the on/off switch in the “off” position. Remove the s front cover per Procedure 7.1.
  • Page 25 C546 Elliptical Fitness Crosstrainerl manner. Exiting the diagnostic program will cause the lift to self center and invalidate the lift calibration just performed. Raise the ramp assembly to a convenient height and slide the lift yoke into the ramp assembly. Hand tighten the four lift yoke mounting screws and then torque them to 240 in/lbs.
  • Page 26 C546 Elliptical Fitness Crosstrainer Procedure 5.4 - Inspecting and Adjusting Belt Alignment and Tension Procedure Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 27 C546 Elliptical Fitness Crosstrainerl 13. Belt tension must now be checked and if necessary corrected. Remember, if it is necessary to change the belt tension, the belt alignment must be maintained. Diagram 5.4 - Drive Unit Input Pulley Stub Tensioner...
  • Page 28 C546 Elliptical Fitness Crosstrainer Diagram 5.5 - Measuring Belt tension 20 lbs 1/4” 16. If the locking tabs on the right and left tension bolts have not been straightened, use pliers to bend the locking tabs out of the way so that the bolts can be turned.
  • Page 29 C546 Elliptical Fitness Crosstrainerl 21. Using your finger, press in on the center of the lower span of the input belt. Compare the pressure required to deflect the input belt to the pressure required to deflect the step up belt.

  • Page 30: Procedure 6.1 - Troubleshooting The Lower And Upper Interconnect Cables

    Troubleshooting the Upper Interconnect Cable Note: There are three different interconnect cable combinations that were used on the C546. Units with serial numbers starting with 4H or 5V manufactured prior to Feb. 8, 1999 used an upper and lower ribbon cable. Units with serial numbers starting with 4H or 5V manufactured after Feb.
  • Page 31 C546 Elliptical Fitness Crosstrainerl interconnect cable is bad. Install a new interconnect cable per Procedure 7.7. If the unit does not operate properly, continue with the next step. 10. Reconnect the original upper interconnect cable to the upper PCA. Troubleshooting the Lower Interconnect Cable 11.
  • Page 32 C546 Elliptical Fitness Crosstrainer 29. If the unit operated correctly when the new interconnect cable was installed, the original interconnect cable is bad. Install a new interconnect cable per Procedure 7.7. If the unit does not operate properly, continue with the next step.
  • Page 33 C546 Elliptical Fitness Crosstrainerl 46. Replace the lower PCA shield. 47. Replace the rear cover. 48. Replace the interconnect cable cover. 49. Check operation as described in Section Four Page 33...

  • Page 34: Procedure 6.2 - Troubleshooting The Keypad And Upper Pca

    C546 Elliptical Fitness Crosstrainer Procedure 6.2 - Troubleshooting the Keypad and Upper PCA (version 1) If the function keys on the electronic console are unresponsive, the problem may be either the upper PCA or keypad. This troubleshooting procedure gives you the information you need to determine which of these components is malfunctioning.
  • Page 35 C546 Elliptical Fitness Crosstrainerl Set the voltmeter to a range that will conveniently read +6 Vdc. Set the circuit breaker in the “on” position. Use a DVM, set for DC volts, and read between pin 6 of J4 and the each of the pins in Table 6.1 (no keys pressed) and Table 6.2 (with the appropriate key pressed)...
  • Page 36 C546 Elliptical Fitness Crosstrainer 13. Position the display enclosure on the display plate. Install the screws that secure the display enclosure to the display plate. 14. Check the operation of the treadmill as described in Section Three of this appendix...
  • Page 37 C546 Elliptical Fitness Crosstrainerl Procedure 6.3 - Troubleshooting the Keypad and Upper PCA (version 2,3) 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 38: Keypad Connector

    C546 Elliptical Fitness Crosstrainer Diagram 6.2 - Upper PCA & Keypad Upper PCA Keypad Connector Keypad Set the on/off switch in the “on” position. If a “key depressed” message is immediately displayed when the EFX is powered up, replace the upper PCA.

  • Page 39: Circuit Description

    C546 Elliptical Fitness Crosstrainerl Procedure 6.4 - Troubleshooting the Speed Sensor Circuit Description The speed sensor is a hall effect sensor. A magnet is mounted on the right hand crankarm and passes the hall effect sensor once per revolution. The output from the speed sensor is a 5 Vdc square wave, the frequency of which indicates the operating speed.
  • Page 40 C546 Elliptical Fitness Crosstrainer Repeat the measurement in step 5 at terminals 1 and 2 of J8 on the lower PCA. If the voltage is missing or significantly low, replace the speed sensor assembly. If you have performed all of the above tests and the stride rate is not displayed when the unit is operated, there are three parts that could cause the problem.
  • Page 41 C546 Elliptical Fitness Crosstrainerl Procedure 6.5 - Troubleshooting the Lift System Note: The lift motor is disabled when the EFX is not being used. The speed sensor must detect motion in order for lift operation to be enabled. In the following procedures, when lift motor movement is being tested the stairarms must be in motion.
  • Page 42 C546 Elliptical Fitness Crosstrainer If you have performed all of the above tests and the lift system is still not functioning, call Precor Technical Support. Set the circuit breaker in the “off” position. Remove the F2 (2 amp slow blow) fuse from the lower PCA.
  • Page 43 They are lower PCA, ribbon cable and upper PCA. Replace only one part at a time. If the new part does not correct the problem replace the original part. If you have performed all of the above tests and there is still no resistance, call Precor Technical Support.
  • Page 44 C546 Elliptical Fitness Crosstrainer If the voltage is still significantly high or low, there are three parts that could cause the problem. There are not any good tests to check these parts other than substituting a known good part. They are lower PCA, ribbon cable and upper PCA. Replace only one part at a time.
  • Page 45 C546 Elliptical Fitness Crosstrainerl Procedure 6.7 - Upper Display does not Illuminate (version 1) Set the on/off switch in the “off” position, unplug the line cord from the wall outlet. Remove the F1 and F2 fuses from the lower PCA. (See Diagram 7.4) Remove the fuses from the input power module.
  • Page 46 C546 Elliptical Fitness Crosstrainer 17. Set the on/off switch in the “on” position. Repeat step 15. If the reading is still significantly low, replace the lower PCA. If the reading is now good, the problem is either the interconnect cable or the upper PCA.
  • Page 47 C546 Elliptical Fitness Crosstrainerl Procedure 6.8 - Upper Display does not Illuminate (version 2,3) Set the on/off switch in the “off” position, unplug the line cord from the wall outlet. Attach the anti-static wrist strap to your arm, then connect the ground lead of the wrist strap to the units frame.
  • Page 48 C546 Elliptical Fitness Crosstrainer 17. If the reading in step 15 is good, skip to step 18. If the reading in step 15 is significantly low, set the on/off switch in the “off” position. Disconnect the interconnect cable (J5) from the lower PCA.
  • Page 49 C546 Elliptical Fitness Crosstrainerl Procedure 6.9 - 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 50 C546 Elliptical Fitness Crosstrainer Set the on/off switch in the “off” position and remove the display housing. Verify the internal chest strap setting is set as shown in Diagram 6.3. Verify that a ferrite bead is installed on the heart rate PCA to upper PCA cable.
  • Page 51 C546 Elliptical Fitness Crosstrainerl 15. Set the on/off switch in the “off” position. Refer to Diagram 6.3 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...
  • Page 52 C546 Elliptical Fitness Crosstrainer 25. Set the on/off switch in the “off” position, and remove the spare jumper from J14 of the heart rate PCA. Re-locate all potential sources of radiation. Set the on/off switch in the “on” position and repeat the procedure in step 6.
  • Page 53 C546 Elliptical Fitness Crosstrainerl Procedure 7.1 - Replacing the Front or Rear Covers Procedure Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. For version 1,2 units, continue with step 2. For version 3 units skip to step 13.
  • Page 54 C546 Elliptical Fitness Crosstrainer Remove the cover by sliding it between the frame uprights. When maintenance operations are complete, slide the cover into place through the frame uprights. 10. Replace and hand tighten the screws that retain the bottom of the cover to the cover bracket.
  • Page 55 C546 Elliptical Fitness Crosstrainerl section to the front cover section. Page 55...
  • Page 56 C546 Elliptical Fitness Crosstrainer 18. If you are removing the front cover section, the right, left and top cover sections must be removed first. Remove the four screws that fasten the frame cover to the frame (See Diagram 7.2). Remove two phillips screws that fasten the bottom of the front cover section to the frame.
  • Page 57 C546 Elliptical Fitness Crosstrainerl Removing and Replacing the Front Cover (version 3) 24. Remove the four lower front cover mounting screws (two each side) from the lower frame. 25. Remove the four upper front cover mounting screws (two each side) from the upper frame.
  • Page 58 C546 Elliptical Fitness Crosstrainer Procedure 7.2 - Replacing the Display Enclosure or Upper PCA (version 1) Anti-static kits (part number 20024-101) can be ordered from Precor. Removing the Display Enclosure Set the on/off switch in the “off” position. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 59 C546 Elliptical Fitness Crosstrainerl Diagram 7.4 - Upper Handlebar Assembly Reading Rack Display Housing Upper PCA Display Backing Plate Interconnect Cable Cover 10. Reposition the upper PCA at its mounting location on the display enclosure (refer to Diagram 7.4). Replace and tighten the upper PCA mounting screws.
  • Page 60 - Replacing the Display Enclosure or Upper PCA (version 2,3) 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 61: Keyboard Connector

    C546 Elliptical Fitness Crosstrainerl Diagram 7.5 - Display Housing Front Panel, Rear View Upper PCA Interconnect Cable Connector Keyboard Connector Position the upper PCA at its mounting location on the display housing front panel (refer to Diagram 7.5). Replace and tighten the upper PCA mounting screws.
  • Page 62 C546 Elliptical Fitness Crosstrainer Procedure 7.4 - 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 63 C546 Elliptical Fitness Crosstrainerl Procedure 7.5 - Replacing the Lower PCA (version 1) Removing the Lower PCA Set the on/off switch in the “off” position. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 64 C546 Elliptical Fitness Crosstrainer Replacing the Lower PCA Position the replacement lower PCA at its mounting position. Install the screws that secure the lower PCA. Connect the cables you disconnected in Step 5. 10. Install the lower PCA shield. 11. Remove the ground lead of the wrist strap from the EFX frame, then remove the wrist strap from your arm.
  • Page 65 C546 Elliptical Fitness Crosstrainerl Procedure 7.6 - Replacing the Lower PCA (version 2,3) Removing the Lower PCA Set the on/off switch in the “off” position. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 66 C546 Elliptical Fitness Crosstrainer Replacing the Lower PCA Position the replacement lower PCA at its mounting position. Install the screws that secure the lower PCA. Connect the cables you disconnected in Step 5. 10. Install the lower PCA shield. 11. Remove the ground lead of the wrist strap from the EFX frame, then remove the wrist strap from your arm.
  • Page 67 Note: There are three different interconnect cable combinations that were used on the C546. Version 1 units manufactured prior to Feb. 8, 1999 used an upper and lower ribbon cable. Version 1units manufactured after Feb. 7, 1999 used a single ribbon cable. Version 2,3 units used an upper and lower telephone cable (RJ45).
  • Page 68 C546 Elliptical Fitness Crosstrainer Two cables are in the main frame tube. The lift motor cable and the interconnect cable(s). Locate the interconnect cable connectors in the access hole and disconnect the interconnect cables. Tape the end of the replacement interconnect cable with the small (16 pin) connector to the upper end of the old interconnect cable (display housing end).
  • Page 69 C546 Elliptical Fitness Crosstrainerl Version 1 units manufactured after Feb. 7, 1999 20. Remove the display housing per Procedure 7.3. Remove the rear cover. 21. Tie one end of a stout string (at least 12’ long) to the upper end of the old interconnect cable (display housing end).
  • Page 70 C546 Elliptical Fitness Crosstrainer 37. Carefully, rotate the center handrail mounting tube back into it’s mounting position. 38. Set the two halves of the clamp in position, be sure that the pins in the rear half of the clamp mate with the holes in the frame, thread and hand tighten the four clamp mounting screws.
  • Page 71 C546 Elliptical Fitness Crosstrainerl Procedure 7.8 - Replacing the Power Entry Module (version 1,2 units manufactured before 10-16-2000) Removing the Power Entry Module Set the on/off switch in the off position, then unplug the power cord from the wall outlet and from the EFX.
  • Page 72 C546 Elliptical Fitness Crosstrainer Note the orientation of the power entry module. The new module must be positioned with the same orientation. Remove the screws that secure the power entry module to the rear assembly bracket. Replacing the Power Entry Module Position the new power entry module at its entry position.
  • Page 73 C546 Elliptical Fitness Crosstrainerl Procedure 7.9 - Replacing the Line Filter (version 1,2 units manufactured before 10-16-2000) Removing the Line Filter Set the on/off switch in the “off’ position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 74 C546 Elliptical Fitness Crosstrainer Procedure 7.10 - Replacing the ON/OFF Switch (version 1,2 units manufactured before 10-16-2000) Removing the ON/OFF Switch Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 75 C546 Elliptical Fitness Crosstrainerl Procedure 7.11 - Replacing the Lift Motor Removing the Lift Motor Note: This procedure references The version 1 & 2 units. The only difference in this procedure is that on version 1, 2 units the lift motor mounts to the ramp via a ramp end cap. Version 3 units lift motors mount to the ramp via a lift yoke.
  • Page 76 C546 Elliptical Fitness Crosstrainer Unthread the ramp end cap or lift yoke from the lift motor drive screw. On version 1,2 units, unthread and remove the leveller. (See Diagram 7.10) Pull the lift motor cable out of the access hole and disconnect the lift motor cables. (See Diagram 7.11).
  • Page 77 C546 Elliptical Fitness Crosstrainerl Set the on/off switch in the “off” position. Do not exit the diagnostic program in the normal manner. Exiting the diagnostic program will cause the lift to self center and invalidate the lift calibration just performed.
  • Page 78 C546 Elliptical Fitness Crosstrainer Procedure 7.12 - Replacing a Crankarm Assembly Removing a Crankarm Assembly Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 79 C546 Elliptical Fitness Crosstrainerl The crankarm removed from the right hand side has a magnet in a recess on the lower backside of the crankarm. The magnet is held in the crankarm by it’s magnetism. Remove the magnet either by prying it out with a thin bladed screwdriver or by placing a heavy piece of steel near the magnet and allowing the it to adhere to the heavy piece of steel.
  • Page 80 C546 Elliptical Fitness Crosstrainer Procedure 7.13 - Replacing a Pillow Block Bearing Current production of C546’s utilize an assembly that consists of the eddy current disk, input pulley assembly and pillow block bearings. The pillow block bearings are permanently attached to the input pulley shaft and can not be removed. If you encounter a situation where a pillow block bearing is damaged and requires replacement, the entire assembly consisting of eddy current disk, input pulley and pillow block bearings must be replaced.
  • Page 81 Procedure 7.14 - Replacing the Eddy Current Disk Assembly Current production of C546’s utilize an assembly that consists of the eddy current disk, input pulley assembly and pillow block bearings. The pillow block bearings are permanently attached to the input pulley shaft and can not be removed. If you encounter a situation where the eddy current disk is damaged and requires replacement, the entire assembly consisting of eddy current disk, input pulley and pillow block bearings must be replaced.
  • Page 82 C546 Elliptical Fitness Crosstrainer Procedure 7.15 - Replacing the Input Pulley Belt Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 83 C546 Elliptical Fitness Crosstrainerl Procedure 7.16 - Replacing the Step-Up Pulley Belt Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 84 C546 Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing the Input Drive Assembly Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 85 C546 Elliptical Fitness Crosstrainerl Remove the input drive assembly. Slide both belts off of the ends of the input drive assembly. 10. Hold the replacement input drive assembly at it’s mounting position and slide the input belt over and past the pillow block bearing on the left side of the input drive assembly. Slide the step belt over and beyond the pillow block bearing on the right side of the input drive assembly.
  • Page 86 C546 Elliptical Fitness Crosstrainer 16. If the drive units was moved in step 15, re-check the drive belt alignment and tensioning per Procedure 5.3. 17. Replace the cover. Page 86...
  • Page 87 C546 Elliptical Fitness Crosstrainerl Procedure 7.18 - Replacing the Step-Up Pulley Assembly Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 88 C546 Elliptical Fitness Crosstrainer Procedure 7.19 - Replacing the Speed Sensor Assembly Removing the Speed Sensor Assembly Set the on off/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 89 14. Replace mounting nut that secures the speed sensor to the frame. 15. Reconnect the speed sensor cable to the lower PCA. 16. Re-install the left rear cover, then check the operation of the C546 as described in Section Four.
  • Page 90 C546 Elliptical Fitness Crosstrainer Procedure 7.20 - Replacing the Eddy Current Magnet Assembly Removing the Magnet Assembly Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.
  • Page 91 C546 Elliptical Fitness Crosstrainerl Check that the eddy current disk is centered between the “legs” of the eddy current magnet. If not, loosen the centering bolts, see Diagram 7.18, and center the eddy current magnet on the eddy current disk. Torque the centering bolts to 150 inch pounds.
  • Page 92 C546 Elliptical Fitness Crosstrainer Procedure 7.21 - Replacing a Stairarm Pivot Block The stairarm pivot has been made an integral part of the stairarm assembly. The pivot block is no longer individually replaceable. The stairarm is provided with a pivot block that is permanently attached to the stairarm.
  • Page 93 C546 Elliptical Fitness Crosstrainerl Procedure 7.22 - 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 94 C546 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 95 C546 Elliptical Fitness Crosstrainerl Procedure 7.23 - Replacing a Stairarm Pedal Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm.
  • Page 96 C546 Elliptical Fitness Crosstrainer Procedure 7.24 - Replacing a Stairarm Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. 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.
  • Page 97 C546 Elliptical Fitness Crosstrainerl Procedure 7.25 - Replacing All or Part of a Ramp Assembly Procedure Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. Remove the rear cover per Procedure 7.1 and pivot both stairarms to the rear of the unit.
  • Page 98 C546 Elliptical Fitness Crosstrainer If you are only replacing a ramp pivot block(s), skip to step 11. If you are replacing a ramp base, remove the nine screws that fasten each ramp track to the ramp base. (see Diagram 7.21) If you are replacing one or more ramp tracks remove the nine ramp track screws associated with the ramp track(s) that you are replacing.
  • Page 99 C546 Elliptical Fitness Crosstrainerl 12. Slide the ramp assembly onto it’s frame pin. Slide the remaining ramp pivot block onto other frame pin. Thread and hand tighten the ramp pivot block mounting screws and then torque them to 120 in/lbs.
  • Page 100 C546 Elliptical Fitness Crosstrainer Procedure 7.26 - Replacing a Handlebar Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. Loosen the screws that fasten the upper end of the handrail into the upper handrail clamp.
  • Page 101 C546 Elliptical Fitness Crosstrainerl Procedure 7.27 - Replacing the Center Handrail Frame Tube (version 1, 2)) Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. Loosen the screws that fasten the upper end of the handrails into the upper handrail clamp.
  • Page 102 C546 Elliptical Fitness Crosstrainer Diagram 7.23 - Center Handrail Frame Tube Interconnect Cable Center Handrail Frame Tube Page 102...
  • Page 103 C546 Elliptical Fitness Crosstrainerl 12. Carefully feed the interconnect cable out of the center handrail frame tube. 13. Hold the replacement center handrail frame tube near it’s mounting position and feed the interconnect cable into the bottom of the center handrail frame tube. After the interconnect cable emerges from the top of the center handrail frame tube, have your assistant hold the frame tube in it’s mounting position.
  • Page 104 C546 Elliptical Fitness Crosstrainer 21. Repeat steps 19 and 20 for the other handrail. Check the operation of the EFX as described in Section Four. Page 104...
  • Page 105 Stub Tensioner Mounting Nut The early C546’s mounted the stub tensioner in a closed slot. If you have a unit with a closed slot it is recommended that the slot be cut open with a hacksaw. Care must be taken not to cut the belt or other adjacent parts.
  • Page 106 C546 Elliptical Fitness Crosstrainer Remove the stub tensioner mounting nut and remove the stub tensioner from the drive unit. Loosely mount the replacement stub tensioner in it’s mounting position. Complete the installation, alignment and tensioning per Procedure 7.15, steps 11 to 15.
  • Page 107 C546 Elliptical Fitness Crosstrainerl Procedure 7.29 - Replacing a Power Entry Module (version 2,3 units manufactured after 10-15-2000) Procedure Note: The power entry module on this EFX is a multifunction unit. It functions as a power entry module, A.C. line fuse holder, on/off switch and A.C.ine filter.
  • Page 108 C546 Elliptical Fitness Crosstrainer Set the replacement power entry module at it’s mounting position, secure the power entry module with the screws removed in step 4. Replace the wires removed in step 3. Connect the blue wire to terminal D and the brown wire to terminal A of the power entry module.
  • Page 109 C546 Elliptical Fitness Crosstrainerl Procedure 7.30 - Replacing a Power Entry Module Fuse (version 2,3 units manufactured after 10-15-2000) Procedure Set the on/off switch in the off position. Remove the A.C. line cord from the A.C. outlet and from the power entry module.
  • Page 110 C546 Elliptical Fitness Crosstrainer Insert the A.C. line cord in the power entry module and the A.C. outlet. Set the on/off switch in the on position and test the EFX per Section Four. Page 110...
  • Page 111 C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.1 - C546 120 Vac ((version 1) Page 111...
  • Page 112 C546 Elliptical Fitness Crosstrainer Block Diagram 8.2 - C546 120 Vac (version 1)) Page 112...
  • Page 113 C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.3 - C546 240 Vac (version 1) AC Line Filter Step-Down Transformer Page 113...
  • Page 114 C546 Elliptical Fitness Crosstrainer Block Diagram 8.4 - C546 240 Vac (version 1) Page 114...
  • Page 115 C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.5 - C546 120 Vac (version 2, 3) Units manufactured before 10-16-2000 Units manufactured after 10-15-2000 Power Entry Module Page 115...
  • Page 116 C546 Elliptical Fitness Crosstrainer Block Diagram 8.6 - C546 120 Vac (version 2, 3) Page 116...
  • Page 117 C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.7 - C546 240 Vac (version 2, 3) Units manufactured before 10-16-2000 Units manufactured after 10-15-2000 Power Entry Module Page 117...
  • Page 118 C546 Elliptical Fitness Crosstrainer Block Diagram 8.8 - C546 240 Vac (version 2, 3) Page 118...

Table of Contents