Precor C542i User manual

C542i Elliptical Fitness Crosstrainer

Page 1

C542i Elliptical Fitness Crosstrainer

Warning: This service manual is for use by Precor trained service providers only.

IfyouarenotaPrecorTrainedServicer,youmustnotattempttoserviceanyPrecorProduct;

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.

Unauthorized Reproduction and Distribution Prohibited By Law

20039-148

C542i Elliptical Fitness Crosstrainer

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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.

General System Information

• The ramp operating system has a battery monitoring system. If the battery voltage falls

below 11 Vdc when ramp movement is initiated or the battery voltage falls below 10 Vdc

after ramp movement has been initiated, ramp movement will be stopped and the message

“NO RAMP LOW VOLTAGE” will be displayed. Ramp motion will not be enabled until such

time as the battery voltage exceeds the above limits.

• 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 three phase output windings is monitored to determine when the unit is in use

and when it is idle. This system also determines the stride rate by determining the operating

speed (output frequency) of the monitored generator winding.

Warning and Caution Statements and General Safety Guidelines

Warning statements indicate a particularly dangerous activity. Warning statements you will find in

this manual include:

• If the EFX has been in recent use, the load resistors and load resistor mounting bracket may

be extremely hot.

• Because this is a self powered unit, it will either be necessary to either equip the unit with

the optional external power supply or have an assistant pedal on the unit while voltage

measurements are being taken. Because of the danger of working on the unit while it is in

motion using the optional external power supply is strongly recommended.

• When the unit is used, stairarms are in motion, the generator will operate and produce

potentially hazardous voltages even when the battery is disconnected.

• To remove power from the EFX, the optional external power supply (when equipped) must

be disconnected from the wall outlet and the red (positive) lead must be disconnected from

the battery. Always ensure that the EFX external power supply is unplugged from the wall

outlet and the red (positive) lead is removed from the battery when you inspect or adjust the

EFX, or when you isolate, remove, or replace an EFX component.

C542i Elliptical Fitness Crosstrainer

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• 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. When you perform maintenance procedures with the covers removed, remove

jewelry (especially from ears and neck), tie up long hair, remove neck ties, and do not wear

loose clothing.

• Exercise caution when touching any wire or electrical component during EFX operation.

• 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:

• When it is necessary to lift or move the EFX, ensure that the EFX has adequate support and

that you use proper lifting techniques.

Safety guidelines you should know and follow include:

• Read the owner’s manual and follow all operating instructions.

• Operate the EFX on a solid, level surface.

• 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. Do not stand or climb on the handlebars, display enclosure, or cover.

• Do not set anything on the handlebars, display enclosure, or cover. Never place liquids on

any part of the EFX, while performing service.

• To prevent electrical shock, keep all electrical components away from water and other

liquids.

• Do not use accessory attachments that are not recommended by the manufacturer-such

attachments might cause injuries.

C542i Elliptical Fitness Crosstrainer

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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

Precor part number 20030-108 belt gauge Straight edge

US and metric end wrench set

US and metric socket wrench set

Torque wrench, 200 in./lbs.

Torque wrench, 200 ft./lbs

C542i Elliptical Fitness Crosstrainer

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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. Precor recommends that you perform the following preventive

maintenance schedule.

After Each Use

• Unplug the optional external power supply (when equipped) from the AC outlet.

• Wipe down the covers, handlebars, stairarm wheels and stairarm ramps with a damp cloth.

Daily Maintenance

Clean the EFX’s frame, covers, stairarms, stairarm ramps and stairarm wheels using water or a

30:1 solution of Simple Green®and water. Wipe the surface of the electronic console with a

damp sponge or soft cloth. 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.

The use of an acid (citric) based cleaner will cause ramp anodizing damage and is not authorized

by Precor.

Weekly Maintenance

• Vacuum underneath the EFX, following these steps:

1. Unplug the optional external power supply (when equipped) from the AC outlet.

2. Place the EFX on its side.

Note:

Place a drop cloth under the EFX to protect the flooring and to ensure that the EFX handrail

is not scratched or damaged.

3. Vacuum the rug or damp mop the floor.

4. Make sure that the floor is dry before returning the EFX to an upright position.

C542i Elliptical Fitness Crosstrainer

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Quarterly Maintenance

1. Remove the rear covers.

2. Check the step up and input belt alignment and tension as in Procedure 5.2.

3. Replace the rear cover.

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.

• Check speed sensor function (is the stride rate displayed when the unit is in operation?). If

not, see Procedure 6.4.

• Visually inspect the drive belts for cracks, fraying or excessive wear.

• When furnished, inspect the optional power supply cords. If a power supply cord is

damaged, install a new power supply.

• Visually examine all wires and check connectors and wire connections. Secure connections

and replace wiring as necessary.

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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. 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. If the access is aborted, it will be necessary to

start over from the beginning. See Diagram 3.1.

Standard Access Codes

Diagnostics Keys RESET,5,1,7,6,5,7,6,1

Odometer Keys RESET,6,5

Club Settings Keys RESET,5,6,5,1,5,6,5

Diagram 3.1 - Display Panel

Key 1 Key 7

C542i Elliptical Fitness Crosstrainer

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Procedure 3.2 - Accessing the Diagnostic Program

The EFX diagnostic software cycles through the following tests:

• Display Test

• Keyboard Test

• Heart Rate Test

• Battery Test

•RPMTest

• Lift Test

• Brake Test

Procedure

1. Start pedalling and continue to pedal as you perform step 2.

2. With the PRECOR banner scrolling, press keys RESET,5,1,7,6,5,7,6,1., sequentially.

3. The message HARDWARE VALIDATION will be displayed for a few seconds.

4. The message DISPLAY TEST will be displayed followed by every LED on the display being

illuminated. Check each LED segment to ensure that all of the segments are illuminated.

Press the ENTER key to advance to the keyboard test.

5. The message KEYBOARD TEST will be displayed followed by a graphical representation of

each key position on the display housing. As each key on the display is pressed the key

representation is turned “off”, indicating that the key is functioning. Check each key in this

manner, including the numeric keyboard. Press and hold the ENTER key for 2 seconds to

advance to the heart rate test.

6. The message HEART RATE TEST will be displayed followed by the unfiltered (U), filtered

(F) and polar (P) heart rate readings if the heart rate option is installed in the EFX and a

chest strap transmitter or a test transmitter is being used. If the heart rate option is not

installed in the EFX the message NO HEART RATE RECEIVER will be displayed instead of

the heart rate readings. Press the ENTER key to advance to the brake test.

7. The message BATTERY TEST will be displayed followed by the battery voltage. Press the

ENTER key to advance to the RPM test.

8. The message RPM TEST will be displayed followed by the pulse (power bit) reading and the

RPM reading. Press the ENTER key to advance to the lift test.

9. The message LIFT TEST will be displayed followed by the ramp level and A/D (analog to

digital) reading. The A/D is the number the system use to track the lift position. The A/D

number will be used in the lift calibration portion of this service manual. (Procedure 5.3).

C542i Elliptical Fitness Crosstrainer

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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.

C542i Elliptical Fitness Crosstrainer

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Procedure 3.3 - Displaying the Odometer

Procedure

1. Start pedalling and continue to pedal as you perform step 2.

2. With the PRECOR banner scrolling, press keys RESET,6,5, sequentially.

3. The message INFORMATION DISPLAY will be displayed for a few seconds.

4. The message ODOMETER will be displayed followed by the total number of strides

accumulated. The total number of strides can be converted to miles by dividing by 2241 or

to kilometers by dividing by 1392.5. Press the ENTER key to advance to total strides.

5. The message TOTAL STRIDES will be displayed followed by the total number of strides

logged on the EFX. Press the ENTER key to advance to hour meter.

6. The message HOUR METER will be displayed followed by the total number of hours that

the EFX has been in use. Press the ENTER key to advance to software version.

7. The message SOFTWARE VERSION will be displayed followed by the software versions of

the upper and lower PCA’s. For example, UPPER 1.01 LOWER 1.01. Press the ENTER key

to advance to error log.

8. The message ERROR LOG will be displayed followed by the error in log position 1. Each

log entry shows the log position, the stride count when the error occurred and the hour

meter when the error occurred. For example; 1 ER21 123456 STR 45678 HRS. The error

log can record up to ten error conditions. The error code in position one will be the most

recent error and the error in position ten will be the oldest error. If more than ten errors have

been logged, only the ten most recent will be displayed. When a new error is logged, each

existing error is pushed down one position and the error in position 10, if any, is lost. Use the

 and keys to move through the log. Pressing and holding the QUICK START key for

four seconds will clear the log. Press the ENTER key to exit the odometer program.

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