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.
C546 Elliptical Fitness Crosstrainer Section One - Things You Should Know C546 Serial Codes and Manufacturing Dates The C546 has been manufactured in three versions. The applicable serial codes and manufacturing dates associated with each version will be detailed below. 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.
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. Caution statements are intended to prevent damage to the EFX as a result of the current activity. Caution statements included in this manual are listed below: • Notice the orientation notch on the PROM.
C546 Elliptical Fitness Crosstrainer • Visually check the EFX before beginning service or maintenance operations. If it is not completely assembled or is damaged in any way, exercise extreme caution while operating and checking the EFX. • When operating the EFX, do not wear loose clothing. Do not wear shoes with heels or leather soles. Check the soles of your shoes and remove any embedded stones. Tie long hair back. • Do not rock the unit.
C546 Elliptical Fitness Crosstrainerl Section Two - Preventive Maintenance Preventive maintenance measures are either scheduled or unscheduled. Scheduled preventive maintenance activities are included here so that you are aware of preventive measures performed on a regular basis. Regular Preventive Maintenance (Owner) Cleanliness of the EFX and its operating environment will keep maintenance problems and service calls to a minimum.
C546 Elliptical Fitness Crosstrainer Quarterly Maintenance 1. Remove front and rear covers. 2. Clean and lubricate the lift motor drive screw with bearing grease. 3. Check the step up and input belt tension as in Procedure 5.3. 4. Replace both covers. On-Site Preventive Maintenance (Service Technician) When you are called to service a EFX, perform these preventive maintenance activities: • Perform the software diagnostics. Check LED and keypad function. Record the odometer reading.
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. The standard access codes use all sequential key presses. The allowable delay between key presses is short. If too much time is taken between key presses the access procedure will be aborted.
C546 Elliptical Fitness Crosstrainer Procedure 3.2 - Accessing the Diagnostic Program 1) (version The EFX diagnostic software cycles through the following tests: • • • • • LED Diagnostics Power Bits Lift Calibration Number Heart Rate Keypad Test Procedure 1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker. 2. Press keys RESET,5,1,7,6,5,7,6,1., sequentially. 3. Watch the upper display as the LED test progresses.
C546 Elliptical Fitness Crosstrainerl Diagram 3.1 - C546 Display Key #7 Key #1 7. Press ENTER, then release. 8. 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. 9. Press ENTER until seven dots illuminate in the left display window. 10. Press each key listed below. Verify that each single dot expands to four dots as the appropriate key is pressed.
C546 Elliptical Fitness Crosstrainer 11. If the left display window column illuminates appropriately as each key is pressed... THEN... The keypad test passed successfully; continue with the next step. OTHERWISE... Troubleshoot per Procedure 6.2 or 6.3 12. End the keypad test by pressing the CROSSRAMP ▼ and RESISTANCE ▲ keys simultaneously.
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 1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker. 2. Press keys RESET,5,1,7,6,5,7,6,1., sequentially. 3. The message DISPLAY TEST will be displayed. 4. All of the LED’s on the display will be illuminated.
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. 14. The A/D number should range between approximately 94 and 209. 15. Press the ENTER key to continue to the next test.
C546 Elliptical Fitness Crosstrainerl Procedure 3.4 - Displaying the Odometer (version 1) Procedure 1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker. 2. With the PRECOR EFX 546 banner scrolling, press keys RESET,6,5, sequentially until the message EFX 546 ODOMETER scrolls across the display window. 3. Press ENTER, then release. Note: The right display window displays the total strides on the EFX 546 (see Diagram 3.2). The number displayed is 102,187.
C546 Elliptical Fitness Crosstrainer 4. 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. 5. Press ENTER, to exit.
C546 Elliptical Fitness Crosstrainerl Procedure 3.5 - Displaying the Odometer (version 2,3) Procedure 1. Plug the power cord into the wall outlet, then turn on the EFX with the circuit breaker. 2. With the PRECOR EFX 546 banner scrolling, press keys RESET,6,5, sequentially. 3. The message ODOMETER will be displayed. 4. The display will then read XXXXXXXX STRIDES. Where XXXXXXX is the total number of strides accumulated on the EFX. 5. Press the ENTER key to continue. 6.
C546 Elliptical Fitness Crosstrainer Procedure 3.6 - Club Settings (version 1) 1. Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially. 2. The maximum workout time will be displayed. The maximum workout may be selected with either of the ▲ or ▼ keys. Press ENTER to continue. 3. The maximum workout time is displayed on the left display window. The maximum workout time is the maximum time a user is allowed to use the unit. 4.
C546 Elliptical Fitness Crosstrainerl Procedure 3.7 - Club Settings (version 2,3) 1. Enter the club settings by pressing keys RESET,5,6,5,1,5,6,5, sequentially 2. The message SELECT LANGUAGE will be displayed. 3. Use the ▲, ▼ keys to select the language to be displayed. 4. When the desired language has been selected, press the ENTER key to continue. 5. The message SELECT UNITS will be displayed. 6. Use the ▲, ▼ keys to select the unit of measure to be displayed. 7.
C546 Elliptical Fitness Crosstrainer Procedure 3.8 - Documenting Software Problems When a problem is found with either the software or upper or lower PCA’s, record the information listed below. 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.
C546 Elliptical Fitness Crosstrainerl Section Four - Checking EFX 546 Operation This section provides you with a quick method of checking EFX operation. Check the operation of the EFX at the end of most maintenance procedures. Procedure 1. Plug the power cord into the wall outlet and set the on/off switch in the “on” position. 2. When the PRECOR EFX 546......WORK OUT SMARTER banner scrolling, press QUICK START. 3.
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.
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 1. 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. 1. Remove the rear cover as described in Procedure 7.1. 2.
C546 Elliptical Fitness Crosstrainer Procedure 5.2 - Calibrating the Lift Motor (version 1,2) 1. 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. 2. In order to calibrate the lift motor, it is necessary to disconnect the lift motor from the ramp assembly. 3. Set the on/off switch in the “off” position. Remove the screws that retain the front cover and remove the front cover.
C546 Elliptical Fitness Crosstrainerl 7. 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. 8. Operate the CROSSRAMP ▲ or CROSSRAMP ▼ keys as required to set the lift calibration number to 200. 9. Rotate the ramp end cap on the lift motor drive screw until the distance from the upper surface of the plastic nut in the ramp end cap to the end of the lift motor drive screw is 1-1/2”.
C546 Elliptical Fitness Crosstrainer Procedure 5.3 - Calibrating the Lift Motor (version 3) 1. In order to calibrate the lift motor, it is necessary to disconnect the lift motor from the ramp assembly. 2. Set the on/off switch in the “off” position. Remove the s front cover per Procedure 7.1. 3. Remove the four screws that retain the lift yoke to the ramp assembly. Support the lift motor and ramp assembly as you separate the lift yoke from the ramp assembly.
C546 Elliptical Fitness Crosstrainerl manner. Exiting the diagnostic program will cause the lift to self center and invalidate the lift calibration just performed. 8. 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. 9. Set the on/off switch in the “on” position. Thoroughly test all lift related functions per Section Four. 10.
C546 Elliptical Fitness Crosstrainer Procedure 5.4 - Inspecting and Adjusting Belt Alignment and Tension Procedure 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Remove both stairarms as described in Procedure 7.24. 4.
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 Step Up Pulley Left Tension Bolt Right Tension Bolt 14. Place a belt gauge (McMaster-Carr 6160K12 or Grainger 3HX33) in the middle of the step up belt and the center of the belt span (see Diagram 5.5).
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. IF... The belt tensioning gauge reads less than 19 pounds THEN... Turn both tension bolts clockwise, in equal quarter-turn increments, until the belt tensioning gauge reads 19 - 21 pounds @1/4” deflection.
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. Diagram 5.6 - Stub Tensioner Stub Tensioner Stub Tensioner Axle Nut Stub Tensioner Adjustment Bolt 22. Loosen the stub tensioner axle nut slightly. Turn the stub tensioner adjustment bolt clockwise to increase or counterclockwise to decrease the input belt tension. 23.
C546 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 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.
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. Remove the shield from the lower PCA. 12. Remove the interconnect cable from the lower PCA. 13. Connect a known good lower interconnect cable between the lower PCA and the upper interconnect cable. 14.
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. 30. Reconnect the original upper interconnect cable to the upper PCA. Version 2,3 31. Set the on/off switch in the “off” position. 32.
C546 Elliptical Fitness Crosstrainerl 46. Replace the lower PCA shield. 47. Replace the rear cover. 48. Replace the interconnect cable cover. 49.
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. Procedure 1. Set the circuit breaker in the “off” position.
C546 Elliptical Fitness Crosstrainerl 4. Set the voltmeter to a range that will conveniently read +6 Vdc. 5. Set the circuit breaker in the “on” position. 6. 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)... Table 6.1. - Voltage Test Points (Function Keys Not Pressed) PLACE THE POSITIVE LEAD OF THE VOLTMETER ON...
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.
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. Procedure 1. Set the on/off switch in the “off” position.
C546 Elliptical Fitness Crosstrainer Diagram 6.2 - Upper PCA & Keypad Upper PCA Keypad Connector Keypad 8. Set the on/off switch in the “on” position. 9. If a “key depressed” message is immediately displayed when the EFX is powered up, replace the upper PCA. 10. If a “key depressed” message is not displayed when the EFX is powered up, replace the display housing front panel. The display housing front panel is equipped with the keypad. 11.
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.
C546 Elliptical Fitness Crosstrainer 6. 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. 7. 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. 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.
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. Before performing this procedure, ensure that the speed sensor is operating normally per Procedure 6.4.
C546 Elliptical Fitness Crosstrainer 6. If you have performed all of the above tests and the lift system is still not functioning, call Precor Technical Support. 7. Set the circuit breaker in the “off” position. Remove the F2 (2 amp slow blow) fuse from the lower PCA. Measure the fuse with an ohmmeter. The measurement should be 1Ω or less. If the fuse is good, re-insert the fuse and skip to step 9. If the fuse is open (∞) or significantly high, replace the fuse.
C546 Elliptical Fitness Crosstrainerl Procedure 6.6 - Troubleshooting the Eddy Current System Note: If the control circuit does not see an output from the speed sensor, it removes power from the eddy current system. Therefore, when it is necessary to check the resistance or take voltage measurements in the eddy current system it will be necessary to slowly turn the flywheels to ensure that the power time out has not occurred.
C546 Elliptical Fitness Crosstrainer 9. 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. If the new part does not correct the problem, replace the original part. 10.
C546 Elliptical Fitness Crosstrainerl Procedure 6.7 - Upper Display does not Illuminate (version 1) 1. Set the on/off switch in the “off” position, unplug the line cord from the wall outlet. 2. Remove the F1 and F2 fuses from the lower PCA. (See Diagram 7.4) 3. Remove the fuses from the input power module. (See Diagram 7.7) 4. Check all four fuses with an ohmmeter. They should read approximately 1Ω or less. Replace any fuse that reads significantly high. 5.
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. 18. Substitute a known good upper PCA. If the upper PCA does not correct the problem, troubleshoot the upper and lower interconnect cables per Procedure 6.1 19.
C546 Elliptical Fitness Crosstrainerl Procedure 6.8 - Upper Display does not Illuminate (version 2,3) 1. Set the on/off switch in the “off” position, unplug the line cord from the wall outlet. 2. Attach the anti-static wrist strap to your arm, then connect the ground lead of the wrist strap to the units frame. 3. Remove the F1 fuse from the lower PCA. (See Diagram 7.5) 4. Remove the fuses from the input power module. (See Diagram 7.7) 5. Check all three fuses with an ohmmeter.
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. 18. 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 one of the interconnect cables or the upper PCA. 19.
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. Refer to Diagram 6.3 and verify that no jumpers are equipped on J13, J14, J15 or J16. Also, verify that there is a jumper equipped on the internal chest strap setting.
C546 Elliptical Fitness Crosstrainer 3. Set the on/off switch in the “off” position and remove the display housing. 4. 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. 5. If the above procedures did not correct the problem, replace the heart rate PCA. No hand held reading - Normal chest strap reading 6. Set the on/off switch in the “on” position and access the diagnostic program (Procedure 3.3).
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 or less. Measure between the “upper right contact” pin on the J1 connector and the upper right hand held heart rate contact on the handlebar. The reading should be 1 Ω or less.
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.
C546 Elliptical Fitness Crosstrainerl Procedure 7.1 - Replacing the Front or Rear Covers Procedure 1. 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. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. Removing and Replacing the Rear Cover (version 1, 2) 2.
C546 Elliptical Fitness Crosstrainer 8. Remove the cover by sliding it between the frame uprights. 9. 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. 11. Replace the cover badge. The cover badge must slide over the lift motor drive screw.
C546 Elliptical Fitness Crosstrainerl section to the front cover section.
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. Lift the rear portion of the frame cover and carefully remove the front cover section.
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. 26. Remove both front cover halves from the unit. 27. When service is complete, set both cover halves in their mounting positions. 28. Replace the four upper front cover mounting screws (two each side) in the upper frame. 29.
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 1. 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. 2. Remove the screws that secure the interconnect cable cover to the bottom of the display backing plate.
C546 Elliptical Fitness Crosstrainerl Diagram 7.4 - Upper Handlebar Assembly Reading Rack Upper PCA Display Housing 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. 11. Reconnect the keypad cable to the upper PCA. 12. Reconnect the interconnect cable to the upper PCA. 13.
C546 Elliptical Fitness Crosstrainer Procedure 7.3 - 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. Removing the Display Housing Front Panel 1. Set the on/off switch in the “off” position.
C546 Elliptical Fitness Crosstrainerl Diagram 7.5 - Display Housing Front Panel, Rear View Interconnect Cable Connector Upper PCA Keyboard Connector 8. 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. 9. Reconnect the keyboard cable to the upper PCA. 10. Reconnect the upper interconnect cable to the upper PCA. 11.
C546 Elliptical Fitness Crosstrainer Procedure 7.4 - Replacing the PROM Anti-static kits (part number 20024-101) can be ordered from Precor. 1. The PROM and the associated printed circuit assembly (PCA) are static sensitive. Antistatic devices must be used and all anti-static precautions must be followed during this procedure. 2. Remove the printed circuit assembly per its associated procedure. 3. Currently we are using two styles of IC software packages.
C546 Elliptical Fitness Crosstrainerl Procedure 7.5 - Replacing the Lower PCA (version 1) Removing the Lower PCA 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Attach the wrist strap to your arm, then connect the ground lead of the wrist strap to the EFX frame. 4. Remove the shield from the lower PCA. 5.
C546 Elliptical Fitness Crosstrainer Replacing the Lower PCA 7. Position the replacement lower PCA at its mounting position. 8. Install the screws that secure the lower PCA. 9. 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. 12. Re-install the rear cover as described in Procedure 7.1, then check the operation of the EFX 546 as described in Section Four.
C546 Elliptical Fitness Crosstrainerl Procedure 7.6 - Replacing the Lower PCA (version 2,3) Removing the Lower PCA 1. 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. 2. Remove the rear cover. 3. Attach the wrist strap to your arm, then connect the ground lead of the wrist strap to the EFX frame. 4. Remove the shield from the lower PCA. 5.
C546 Elliptical Fitness Crosstrainer Replacing the Lower PCA 7. Position the replacement lower PCA at its mounting position. 8. Install the screws that secure the lower PCA. 9. 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. 12. Re-install the rear cover, then check the operation of the C556 as described in Section Four.
C546 Elliptical Fitness Crosstrainerl Procedure 7.7 - Replacing the Lower and/or Upper Interconnect Cables Before you install a new interconnect cable, ensure that the interconnect cable is defective as described in Procedure 6.1. Procedure 1. 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. 2.
C546 Elliptical Fitness Crosstrainer 6. 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. 7. 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). 8.
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). 22. Carefully pull the old interconnect cable out of the access hole near the lower PCA while feeding the string into the unit. When the string is fully into the unit, remove the old interconnect cable from the string. 23.
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. Tighten the upper clamp mounting screws before the lower clamp mounting screws. (See Diagram 7.24) 39. Tighten the upper handrail clamp mounting screws. 40.
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 1. Set the on/off switch in the off position, then unplug the power cord from the wall outlet and from the EFX. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know. 2. Release the fuse drawer from the power entry module. Remove the fuse drawer.
C546 Elliptical Fitness Crosstrainer 6. 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 7. Position the new power entry module at its entry position. Make sure that the module is oriented correctly. Install the screws that secure the power entry module to the EFX frame. 8.
C546 Elliptical Fitness Crosstrainerl Procedure 7.9 - Replacing the Line Filter (version 1,2 units manufactured before 10-16-2000) Removing the Line Filter 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3.
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 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3.
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. When replacing a lift motor on a version unit substitute the word lift yoke for ramp end cap See Diagram 5.3. 1. Set the on/off switch in the “off” position.
C546 Elliptical Fitness Crosstrainer 3. 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) 4. Pull the lift motor cable out of the access hole and disconnect the lift motor cables. (See Diagram 7.11). 5. Remove the hitch pin from the clevis pin. Remove the clevis pin from the lift motor. Diagram 7.11 - Lift Motor Mounting Lift Motor Clevis Pin Ground Wire Hitch Pin Lift Motor Cable Access Hole 6.
C546 Elliptical Fitness Crosstrainerl 9. 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. 10. On version 1, 2 units, raise the ramp assembly to a convenient height and slide the ramp end cap into the ramp assembly. Hand tighten the four ramp end cap mounting screws and then torque them to 100 in/lbs. 11.
C546 Elliptical Fitness Crosstrainer Procedure 7.12 - Replacing a Crankarm Assembly Removing a Crankarm Assembly 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Remove the stairarm assembly as described in Procedure 7.24.
C546 Elliptical Fitness Crosstrainerl 6. 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. Replacing a Crank Arm Assembly 7.
C546 Elliptical Fitness Crosstrainer Procedure 7.13 - Replacing a Pillow Block Bearing 1. 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.
C546 Elliptical Fitness Crosstrainerl Procedure 7.14 - Replacing the Eddy Current Disk Assembly 1. 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.
C546 Elliptical Fitness Crosstrainer Procedure 7.15 - Replacing the Input Pulley Belt 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Remove the stairarm assemblies as described in Procedure 7.24. 4. Remove the crankarm assemblies as described in Procedure 7.
C546 Elliptical Fitness Crosstrainerl Procedure 7.16 - Replacing the Step-Up Pulley Belt 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Remove the stairarm assemblies as described in Procedure 7.24. 4.
C546 Elliptical Fitness Crosstrainer Procedure 7.17 - Replacing the Input Drive Assembly 1. 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. 2. Remove the rear cover. 3. Remove the stairarm assemblies as described in Procedure 7.24. 4. Remove the crankarm assemblies as described in Procedure 7.12. 5.
C546 Elliptical Fitness Crosstrainerl 9. 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. 11. Replace the input drive assembly.
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.
C546 Elliptical Fitness Crosstrainerl Procedure 7.18 - Replacing the Step-Up Pulley Assembly 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Remove the stairarm assemblies as described in Procedure 7.24. 4.
C546 Elliptical Fitness Crosstrainer Procedure 7.19 - Replacing the Speed Sensor Assembly Removing the Speed Sensor Assembly 1. 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. Note: The speed sensor magnet must be mounted in the right hand crankarm on version 1, 2 units and in the left hand crankarm of version 3 units.
C546 Elliptical Fitness Crosstrainerl 7. Replace mounting nut that secures the speed sensor to the frame. 8. Reconnect the speed sensor cable to the lower PCA. 9. Re-install the rear cover, then check the operation of the C546 as described in Section Four. 10. Remove the left rear cover. 11. Disconnect the speed sensor cable from the lower PCA. Diagram 7.17B - Speed Sensor Mounting (version 3) Speed Sensor 12. Remove the mounting nut that secures the speed sensor assembly to the frame.
C546 Elliptical Fitness Crosstrainer Procedure 7.20 - Replacing the Eddy Current Magnet Assembly Removing the Magnet Assembly 1. 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. 2. Remove the rear cover. 3. Disconnect the magnet cable from the magnet assembly. 4.
C546 Elliptical Fitness Crosstrainerl 7. 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. 8. Reconnect the magnet cable to the magnet assembly. 9. Re-install the rear cover, then check the operation of the EFX as described in Section Four.
C546 Elliptical Fitness Crosstrainer Procedure 7.21 - Replacing a Stairarm Pivot Block 1. 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. If the pivot block is defective, the stairarm must be replaced per Procedure 7.24.
C546 Elliptical Fitness Crosstrainerl Procedure 7.22 - Replacing a Wheel Assembly Procedure 1. Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. 2. 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 8. If the wheel being replaced has a small (8-32) mounting screw, continue with step 3.
C546 Elliptical Fitness Crosstrainer 7. 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. 8. 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. 9. Install the replacement wheel assembly in the wheel cover. Install and hand tighten the two wheel axle bolts. Torque the wheel cover bolts to 15 foot-pounds.
C546 Elliptical Fitness Crosstrainerl Procedure 7.23 - Replacing a Stairarm Pedal 1. Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet 2. Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm. 3. Remove the stairarm pedal from the stairarm. 4. Set the replacement stairarm pedal at it’s mounting position on the stairarm. 5. Install and hand tighten the stairarm pedal mounting hardware removed in step 2.
C546 Elliptical Fitness Crosstrainer Procedure 7.24 - Replacing a Stairarm 1. Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. 2. Remove the rear cover per Procedure 7.1. 3. Remove the retaining clip that fastens the stairarm pivot block to the crankarm. Slide the stairarm off of the crankarm. 4. Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm. 5. Remove the stairarm pedal from the stairarm. 6.
C546 Elliptical Fitness Crosstrainerl Procedure 7.25 - Replacing All or Part of a Ramp Assembly Procedure 1. Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. 2. Remove the rear cover per Procedure 7.1 and pivot both stairarms to the rear of the unit. 3. Remove the four screws that fasten the ramp end cap to the ramp assembly. Slide the ramp end cap out of the ramp assembly and rotate the ramp assembly toward the rear of the unit. 4.
C546 Elliptical Fitness Crosstrainer 7. If you are only replacing a ramp pivot block(s), skip to step 11. 8. If you are replacing a ramp base, remove the nine screws that fasten each ramp track to the ramp base. (see Diagram 7.21) 9. 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. Diagram 7.21 - Ramp Assembly Ramp End Cap Ramp Track Ramp Track Ramp Track Screw Ramp Base Lift Motor Drive Screw 10.
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. 13. If ramp end cap has been replaced or the ramp end cap was rotated on the lift motor drive screw, recalibrate the lift motor per Procedure 5.2. 14. Align the ramp assembly with the ramp end cap and slide the ramp end cap into the ramp assembly. 15.
C546 Elliptical Fitness Crosstrainer Procedure 7.26 - Replacing a Handlebar 1. Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. 2. Loosen the screws that fasten the upper end of the handrail into the upper handrail clamp. 3. Loosen the four set screws that fasten the lower end of the handrail into the frame tube. 4. Slide the upper end of the handrail out of the upper handrail clamp and then slide the lower end of the handrail off of the frame tube. 5.
C546 Elliptical Fitness Crosstrainerl Procedure 7.27 - Replacing the Center Handrail Frame Tube (version 1, 2)) 1. Set the on/off switch in the “off” position, then unplug the power cord from the wall outlet. 2. Loosen the screws that fasten the upper end of the handrails into the upper handrail clamp. 3. Loosen the four set screws that fasten the lower end of the handrails into the frame tubes. 4.
C546 Elliptical Fitness Crosstrainer Diagram 7.
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.
C546 Elliptical Fitness Crosstrainer 21. Repeat steps 19 and 20 for the other handrail. 22. Check the operation of the EFX as described in Section Four.
C546 Elliptical Fitness Crosstrainerl Procedure 7.28 - Replacing the Stub Tensioner 1. 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. 2. Remove the rear cover as described in Procedure 7.1. 3. Loosen the tension adjustment bolt to remove tension from the input belt. See Diagram 7.25. Diagram 7.
C546 Elliptical Fitness Crosstrainer 5. Remove the stub tensioner mounting nut and remove the stub tensioner from the drive unit. 6. Loosely mount the replacement stub tensioner in it’s mounting position. 7. Complete the installation, alignment and tensioning per Procedure 7.15, steps 11 to 15.
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. 1. 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. 2. Remove the rear cover per Procedure 7.1. Diagram 7.
C546 Elliptical Fitness Crosstrainer 7. Set the replacement power entry module at it’s mounting position, secure the power entry module with the screws removed in step 4. 8. 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. 9. Replace the cover per Procedure 7.1. 10. Insert the A.C. line cord in the power entry module and the A.C. outlet. 11. Set the on/off switch in the on position and test the EFX per Section Four.
C546 Elliptical Fitness Crosstrainerl Procedure 7.30 - Replacing a Power Entry Module Fuse (version 2,3 units manufactured after 10-15-2000) Procedure 1. 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. 2. Using a thin bladed screwdriver, carefully pry the fuse access door open (See Diagram 7.28). Diagram 7.28 - Power Entry Module Fuse Fuse Module Power Entry Module Fuse Fuse Access Door 3.
C546 Elliptical Fitness Crosstrainer 7. Insert the A.C. line cord in the power entry module and the A.C. outlet. 8. Set the on/off switch in the on position and test the EFX per Section Four.
C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.
C546 Elliptical Fitness Crosstrainer Block Diagram 8.
C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.
C546 Elliptical Fitness Crosstrainer Block Diagram 8.
C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.
C546 Elliptical Fitness Crosstrainer Block Diagram 8.
C546 Elliptical Fitness Crosstrainerl Wiring Diagram 8.
C546 Elliptical Fitness Crosstrainer Block Diagram 8.
