Precor 546 Elliptical - Page 6 - Answered Questions & Fixed issues

Procedure 2.3 - Accessing the User Parameter Program This procedure allows you to change the following settings: • Set Measurement Units • Enable/Disable Password • Set User Name Procedure 1. Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. 2. Press keys STOP,5,6,7,1 sequentially. 3. The display will momentarily read SELECT UNITS 4. The currently selected measurement unit will then be displayed. 5. Use the UP, DOWN arrow keys to toggle between U.S. STANDARD and METRIC. 6. Press the ENTER key to select the currently displayed measurement unit. 7. The display will momentarily read, PASSWORD 8. Use the UP, DOWN arrow keys to select either PASSWORD ENABLED or PASSWORD DISABLED 9. Press the STOP or ENTER key to exit the program.

Precor Error 01, Memory, RAM, EEPROM Test Error Probable Cause This error message almost always indicate an upper PCA problem when they are consistently displayed. Failures causing this error message to be displayed are rare. Corrective Action If the error message is consistently displayed when the unit is powered up, the upper PCA should be replaced. It is possible to see this message displayed intermittently due to external causes. If the units A.C. input significantly dips during the power up test sequence the test could fail resulting in this message being displayed. Treadmills operating on non-dedicated A.C. circuits may see this message displayed on an intermittent basis. Here's a link to more error codes: Error Code List for Precor Fitness Equipment

Precor Error E2, Lift Error Probable Cause Error would occur if the incline is unable to move or if the incline position potentiometer is not functioning. When this error occurs, all lift motor and drive motor motion is ceased and the display will go blank except for the error displayed. Corrective Action Troubleshoot as errors 40 and 42. Precor Error Code E2 Precor Error 40, No Lift Motion Detected Probable Cause 1. Blown lift fuse in lower PCA. 2. Lift motor is physically jammed and not able to move. 3. Bad lower PCA. 4. Bad lift capacitor. 5. Bad lift motor winding. 6. Bad interconnect cable between upper and lower PCA. 7. Bad upper PCA. Corrective Action

1. Check the lift fuse from the lower PCA. Using an ohmmeter, the fuse should measure 1 ohm or less. If the reading is significantly high, replace the fuse. If the fuse is open, refer to steps 3 and 4 before continuing.
2. Disconnect the lift motor from the ramp (elliptical) or lift platform (treadmill). If the lift nut or lift tube is jammed against the motor housing, turn the lift tube or lift nut away from the motor housing. If the lift was jammed, refer to step 3 before continuing. Calibrate the lift motor per the proper procedure for the unit being serviced and reattach the lift motor to the ramp (elliptical) or lift platform (treadmill). NOTICE: You must find and repair the cause for the jammed lift. Only re-calibrating the lift motor will not solve the problem.
3. One of two modes can cause the lower PCA to fail. The lift switch could fail in an operated condition. If this happens the lift will move (either up or down) as soon as the unit powers up. The usual result is that the lift will be physically jammed as explained above, and probably also being cause for the lift fuse to blow. The lift switch could also fail in an open condition. If this happened, the lift would not operate in one direction. If either of these conditions occur the lower PCA needs replaced.
4. Most units have the lift capacitor mounted inside the lift motor, and others use external lift capacitors. This information applies to units with the external lift capacitors. If the lift capacitor is shorted the lift fuse blows. Check the capacitor for a short using an ohm meter. Disconnect the capacitor from the lift motor and test. A good capacitor reads in the millions of ohms. Replace the capacitor if the reading is significantly low. Capacitor can also fail in the open condition which would result with the lift motor trying to run but not having normal power. Test the capacitor by measuring AC voltage across it. A good capacitor will read AC peak voltage while an open capacitor reads AC RMS voltage.
5. When a lift motor winding is bad the lift will not operate in one or both directions depending upon the exact fault in the motor. Check the lift motor winding with an ohm meter. AC lift motors have a split winding (3 wires) and DC lift motors will have a single winding. Both windings must be checked on an AC lift motor. Normal winding readings could vary anywhere between 1 and 60 ohms, depending on the lift motor being tested. See the proper service manual for the motor being tested.
6. Test unit with a known good interconnect cable. Replace the interconnect cable if necessary.
7. Test unit with a known good upper PCA. Replace the lower PCA if necessary.

Precor Error Code 40 Precor Error Code 42 Error Code: 42 Manufacturer: Precor Model: All Models Error Description: Error 42, Lift Position Value Out of Range. Error 42 is displayed when the lift position reported by the lift position potentiometer is found to be outside its set limits. If an Error 42 has occurred, it is important to know the physical position of the lift when the error occurred. It is possible the lift is physically out of range or jammed. In this case, the Error 42 is a secondary symptom and the issue should be approached as an Error 40. Possible Reason:

1. Bad or intermittent connection in the lift motor controller.
2. The lift motor requires calibration.
3. The lift motor potentiometer is bad.
4. The lower PCA to upper PCA cable is bad.
5. The lower PCA is bad.
6. The upper PCA is bad.

Recommended Action:

1. Intermittent connections can be difficult to locate. If the Error 42 condition is intermittent, a connection issue is probably the cause. This is definitely true if the Error 42 occurred while the lift was within its normal physical range. Inspect the lift potentiometer connector and repair connection if necessary. If the intermittent connection cannot be found or corrected, replace the lift motor. A lift calibration number of 0 or 255 indicates an open or shorted potentiometer connection. This means the problem could be anywhere between the lift motor and the upper PCA. Typically it can be identified and tracked using an ohmmeter.
2. Using the appropriate service manual for the unit being tested, refer to the lift calibration procedure. If the information in the service manual doesn't match the lift position/physical lift position of the unit, recalibrate the lift motor. [Something caused the lift motor to be out of calibration. Investigate for cause and correct. Simply recalibrating the lift motor will not solve the problem.]
3. If the lift calibration number is not 0 or 255 and does not change when the lift motor turns, replace the lift motor.
4. Check continuity of the interconnect cable or swap with a known good interconnect cable to verify if cable is bad.
5. Swap the lower PCA with a known good lower PCA to verify if the lower PCA is bad.
6. Swap the upper PCA with a know good upper PCA to verify if the upper PCA is bad.

Lift Position Value Out of Range Precor Error 42

Adjusting Tension on a Treadmill Running Belt It is necessary to properly tension a treadmill belt when it is replaced. After time, a belt can stretch and may begin to slip. When this happens, it is necessary to adjust the tension of the running belt to stop it from slipping. Manufacturers of treadmills generally agree on one of three procedures for how to tension a treadmill running belt.

1. Adjust for no slippage of the treadmill walking belt on the front roller (Often referred to as the "Stomp Test")
   1. This procedure works well for a previously installed belt that is now slipping.
   2. Underside of belt should be free of any glazing/wax buildup.
   3. Rollers must also be free of wax buildup.
   4. Be sure belt tracking/centering is correct before proceeding.
   5. The most popular speed for this adjustment is 2mph to 3mph.
   6. Try to slow the belt by applying pressure with your foot against the belt movement while grasping the handrails. If the running belt slow, slips or stops (and the front roller does not) adjust BOTH adjustment bolts 1/4 turn clockwise. Test again and repeat adjustment if necessary.
2. This procedure requires two belt gauges or calipers
   1. This procedure works well when installing a new belt.
   2. This procedure requires you to stretch the belt. Depending on the manufacturer*, this varies between .4 and .6 percent. A dial on the gauge or caliper will indicate the amount of stretch. *Consult the owner/service manual for proper tension.
   3. If you are working on a previously tensioned belt you will need to release the tension before attaching the gauges or calipers.
3. Gauges or Calipers unavailable
   1. Release the tension on the belt.
   2. Using a yard stick or tape measure, place two marks on the left and right edges of the belt and deck 36 inches apart (or 50 inches if you prefer).
   3. Adjust the left and right tensioning bolts until both sides measure 36 3/16 inches (or 50 1/4). This is equal to .5% of stretch.
   4. Test for proper tracking and tension, adjust if necessary.

How to Tension Treadmill Walking Belt that Slips

Precor Error 05, Key Depressed at Power Up Probable Cause 1. A key is permanently depressed on the display. 2. An interface chip (IC) has failed in the upper PCA's keypad. 3. Liquid (cleaning solution or sweat) may be on the surface of a touch sensitive display. Corrective Action

1. Disconnect the keypad cable from the upper PCA. Reset power to the machine. If the Error 05 is eliminated, the keypad is the cause and should be replaced.
2. Disconnect the keypad cable from the upper PCA. Reset power to the machine. If the Error 05 still appears, the upper PCA* is the cause and should be replaced. *Upper PCA's most commonly do not come with software. Remove the software (chip) from the existing upper PCA prior to replacement and install into the new upper PCA.
3. Wipe away all liquid from the touch sensitive display. Reset power to the unit. If the Error 05 is eliminated, the liquid was the cause.

This link will take you to the starting point for the parts for this manufacturer. You will need to narrow your search according to the model and serial number of the machine. Precor Equipment Repair Parts Treadmill Belts Ramp Sleeves SPORTSMITH...

Precor Error 44, Un-commanded Lift Motion Probable Cause 1. Intermittent or bad connection in the lift position sensor(potentiometer). 2. Lift position sensor (potentiometer) is bad. 3. Lower PCA is bad. Corrective Action

1. Bad or intermittent connection of the lift position sensor (potentiometer) is the most common cause of the error 44. Inspect all wiring and connections related to the lift position sensor (potentiometer). Repair or replace wiring connections as necessary.
2. Monitor the lift position number displayed while operating the lift in diagnostics mode. If the reading makes large changes or is erratic, the lift position sensor (potentiometer) is likely bad. Replace the lift position sensor (potentiometer) or lift motor if the lift position sensor (potentiometer) is internal to the lift motor.
3. If the lift moves without any command entered either manually or through a program, replace the lower PCA.

Precor Error Code 44

The power leads Black/red will determine the direction that the motor will turn. If the leads have been switched to the wrong terminals at the lower PCA it will run backwards even if the black and red line up when the motor is plugged in. Check to see if the power cable on the lower board is in the right configuration. I've seen the terminals get switched when a new lower board is installed.

Precor Error Code 23 Error Code: 23 Manufacturer: Precor Model: All Models Error Description: Error 23, Motor Pulses Missing after Start Up - Indication that the speed sensor signal was lost while the unit was in operation. Possible Reason:

1. The line of sight between the speed sensor and the speed sensor target is obstructed.
2. Incorrect gap between the speed sensor and the speed sensor target.
3. Incorrect adjustment of the speed sensor potentiometer (when equipped).
4. Intermittent connection of speed sensor or drive motor wiring.
5. Badly worn drive motor brushes not able to make proper contact with drive motor commutator.
6. Faulty lower PCA.
7. Faulty interconnect cable between upper and lower PCA.
8. Faulty upper PCA.

Recommended Action:

1. Using a static safe vacuum cleaner, carefully vacuum out the drive motor compartment. Be sure to thoroughly clean the area between the speed sensor and the speed sensor target.
2. Inspect the gap of the speed sensor to the speed sensor target. Proper gap is 3/16" and the speed sensor photo eye should be aimed at the larger portion of the targets wedge shaped section. If unit has a magnetic speed sensor, the gap between the end of the sensor and the flywheel tooth needs to be 3/16".
3. Locate the speed sensor potentiometer (when equipped) on the lower PCA. Set the speed sensor potentiometer to mid-range. Start the treadmill and increase speed to 6 mph. Carefully adjust the speed sensor potentiometer until the treadmill is operating the smoothest. Increase the speed to full speed and again adjust the speed sensor potentiometer until the treadmill is operating the smoothest. These two adjustments are typically small and are generally only a matter of fine tuning.
4. Test all wiring and wire connections of the speed sensor and drive motor. Replace or repair necessary wire connections or wiring.
5. Inspect and replace drive motor brushes if necessary.
6. Determine if the lower PCA is bad by swapping with a known good lower PCA.
7. Determine if the interconnect cable is bad by swapping with a know good cable.
8. Determine if the upper PCA is bad by swapping with a know good upper PCA.

Precor Error 16, AC Input Voltage Too Low Probable Cause 1. AC input voltage is incorrect. 2. Treadmill operating on undersized AC wiring and/or is drawing high current. Corrective Action

1. Verify AC feed into the building's circuit breaker is correct and connected to the proper transformer tap.
2. The AC wiring must be sized to handle 20 amps of current over the loop length of the AC wiring. Voltage drop across the AC input wiring is a result of the length of the wire run multiplied by the amount of current being demanded by the treadmill. The longer the run and the higher the current the large the wire must be.Verify the unit is connected to an isolated and dedicated 20 amp circuit.

Precor Error 16

Precor Error Code 22 Error Code: 22 Manufacturer: Precor Model: All Models Error Description: Error 22, No Motor Pulses at Start Up - Error indicates that the display has sent a command for the drive motor to start, however, the speed sensor has not returned the signal acknowledging that the drive motor has started. Possible Reason:

1. The line of sight between the speed sensor and the speed sensor target is obstructed.
2. Badly worn drive motor brushes.
3. Incorrect gap between the speed sensor and the speed sensor target.
4. Incorrect adjustment of the speed sensor potentiometer (when equipped).
5. Inoperative speed sensor.
6. Faulty lower PCA.
7. Faulty interconnect cable between upper and lower PCA.
8. Faulty upper PCA.

Recommended Action:

1. Using a static safe vacuum cleaner, carefully vacuum out the drive motor compartment. Be sure to thoroughly clean the area between the speed sensor and the speed sensor target.
2. Bady worn drive motor brushes cannot make proper contact with the motor commutator, therefore the drive motor will not start when voltage is applied. Inspect and replace drive motor brushes if necessary.
3. Inspect the gap of the speed sensor to the speed sensor target. Proper gap is 3/16" and the speed sensor photo eye should be aimed at the larger portion of the targets wedge shaped section. If unit has a magnetic speed sensor, the gap between the end of the sensor and the flywheel tooth needs to be 3/16".
4. Locate the speed sensor potentiometer (when equipped) on the lower PCA. Set the speed sensor potentiometer to mid-range. Start the treadmill and increase speed to 6 mph. Carefully adjust the speed sensor potentiometer until the treadmill is operating the smoothest. Increase the speed to full speed and again adjust the speed sensor potentiometer until the treadmill is operating the smoothest. These two adjustments are typically small and are generally only a matter of fine tuning.
5. An inoperative speed sensor will allow the drive motor to start and run briefly before the error appears. If able to access the speed sensor wiring, measure the DC voltage between the speed sensor leads. Two of the leads will always read about 5 VDC. Two will toggle between 0 and 5 VDC as you slowly turn the speed sensor target. If both measurements are not seen, the speed sensor needs replaced. Some units have the speed sensor mounted on the lower PCA and the lower PCA needs replaced.
6. Determine if the lower PCA is bad by swapping with a known good lower PCA.
7. Determine if the interconnect cable is bad by swapping with a know good cable.
8. Determine if the upper PCA is bad by swapping with a know good upper PCA.

Precor Error Code 22

Precor Error 05, Key Depressed at Power Up Probable Cause 1. A key is permanently depressed on the display. 2. An interface chip (IC) has failed in the upper PCA's keypad. 3. Liquid (cleaning solution or sweat) may be on the surface of a touch sensitive display. Corrective Action

1. Disconnect the keypad cable from the upper PCA. Reset power to the machine. If the Error 05 is eliminated, the keypad is the cause and should be replaced.
2. Disconnect the keypad cable from the upper PCA. Reset power to the machine. If the Error 05 still appears, the upper PCA* is the cause and should be replaced. *Upper PCA's most commonly do not come with software. Remove the software (chip) from the existing upper PCA prior to replacement and install into the new upper PCA.
3. Wipe away all liquid from the touch sensitive display. Reset power to the unit. If the Error 05 is eliminated, the liquid was the cause.

Precor Error Code 05

Precor Error Code 26 Error Code: 26 Manufacturer: Precor Model: All Models Error Description: Error 26, Motor Pulse Width Incorrect - Observation of the speed sensor signal and verification the signal from the speed sensor is appropriate for the requested speed. If an incorrect or erratic speed sensor signal is detected the error appears. Possible Reason:

1. The line of sight between the speed sensor and the speed sensor target is obstructed.
2. Incorrect gap between the speed sensor and the speed sensor target.
3. Incorrect adjustment of the speed sensor potentiometer (when equipped).
4. Damaged speed sensor target.

Recommended Action:

1. Using a static safe vacuum cleaner, carefully vacuum out the drive motor compartment. Be sure to thoroughly clean the area between the speed sensor and the speed sensor target.
2. Inspect the gap of the speed sensor to the speed sensor target. Proper gap is 3/16" and the speed sensor photo eye should be aimed at the larger portion of the targets wedge shaped section. If unit has a magnetic speed sensor, the gap between the end of the sensor and the flywheel tooth needs to be 3/16".
3. Locate the speed sensor potentiometer (when equipped) on the lower PCA. Set the speed sensor potentiometer to mid-range. Start the treadmill and increase speed to 6 mph. Carefully adjust the speed sensor potentiometer until the treadmill is operating the smoothest. Increase the speed to full speed and again adjust the speed sensor potentiometer until the treadmill is operating the smoothest. These two adjustments are typically small and are generally only a matter of fine tuning.
4. Inspect the speed sensor target for any scratches or tears that could cause incorrect readings. Replace the speed sensor target if necessary.

Precor Error Code 26

Precor Error 40, No Lift Motion Detected Probable Cause 1. Blown lift fuse in lower PCA. 2. Lift motor is physically jammed and not able to move. 3. Bad lower PCA. 4. Bad lift capacitor. 5. Bad lift motor winding. 6. Bad interconnect cable between upper and lower PCA. 7. Bad upper PCA. Corrective Action

1. Check the lift fuse from the lower PCA. Using an ohmmeter, the fuse should measure 1 ohm or less. If the reading is significantly high, replace the fuse. If the fuse is open, refer to steps 3 and 4 before continuing.
2. Disconnect the lift motor from the ramp (elliptical) or lift platform (treadmill). If the lift nut or lift tube is jammed against the motor housing, turn the lift tube or lift nut away from the motor housing. If the lift was jammed, refer to step 3 before continuing. Calibrate the lift motor per the proper procedure for the unit being serviced and reattach the lift motor to the ramp (elliptical) or lift platform (treadmill). NOTICE: You must find and repair the cause for the jammed lift. Only re-calibrating the lift motor will not solve the problem.
3. One of two modes can cause the lower PCA to fail. The lift switch could fail in an operated condition. If this happens the lift will move (either up or down) as soon as the unit powers up. The usual result is that the lift will be physically jammed as explained above, and probably also being cause for the lift fuse to blow. The lift switch could also fail in an open condition. If this happened, the lift would not operate in one direction. If either of these conditions occur the lower PCA needs replaced.
4. Most units have the lift capacitor mounted inside the lift motor, and others use external lift capacitors. This information applies to units with the external lift capacitors. If the lift capacitor is shorted the lift fuse blows. Check the capacitor for a short using an ohm meter. Disconnect the capacitor from the lift motor and test. A good capacitor reads in the millions of ohms. Replace the capacitor if the reading is significantly low. Capacitor can also fail in the open condition which would result with the lift motor trying to run but not having normal power. Test the capacitor by measuring AC voltage across it. A good capacitor will read AC peak voltage while an open capacitor reads AC RMS voltage.
5. When a lift motor winding is bad the lift will not operate in one or both directions depending upon the exact fault in the motor. Check the lift motor winding with an ohm meter. AC lift motors have a split winding (3 wires) and DC lift motors will have a single winding. Both windings must be checked on an AC lift motor. Normal winding readings could vary anywhere between 1 and 60 ohms, depending on the lift motor being tested. See the proper service manual for the motor being tested.
6. Test unit with a known good interconnect cable. Replace the interconnect cable if necessary.
7. Test unit with a known good upper PCA. Replace the lower PCA if necessary.

Precor Error Code 40

Precor Error 03, Memory, RAM, EEPROM Test Error Probable Cause This error message almost always indicates an upper PCA problem when it is consistently displayed. Failures causing this error message to be displayed are rare. Corrective Action If the error message is consistently displayed when the unit is powered up, the upper PCA should be replaced. It is possible to see this message displayed intermittently due to external causes. If the units A.C. input significantly dips during the power up test sequence the test could fail resulting in this message being displayed. Treadmills operating on non-dedicated A.C. circuits may see this message displayed on an intermittent basis. Precor Error Code 03 E03 EEPROM Test Error

Precor Error 16, AC Input Voltage Too Low Probable Cause 1. AC input voltage is incorrect. 2. Treadmill operating on undersized AC wiring and/or is drawing high current. Corrective Action

1. Verify AC feed into the building's circuit breaker is correct and connected to the proper transformer tap.
2. The AC wiring must be sized to handle 20 amps of current over the loop length of the AC wiring. Voltage drop across the AC input wiring is a result of the length of the wire run multiplied by the amount of current being demanded by the treadmill. The longer the run and the higher the current the large the wire must be.Verify the unit is connected to an isolated and dedicated 20 amp circuit.

Precor Error 16

Precor Error 30, 31, 32 and 33, Communications Error Probable Cause 1. Bad interconnect cable between upper PCA and lower PCA. 2. Interconnect cable is mistakenly plugged into the CSAFE connector at the upper PCA. 3. Elliptical 5.17 equipped with old software version 1.01 in upper and lower PCA. 4. Upper and lower PCAs have mismatched software. 5. Another component plugged onto the PCA is overloading the +5VDC power supply. 6. Bad lower PCA. 7. Bad upper PCA. Corrective Action

1. Test unit with a know good interconnect cable or test the interconnect cable for continuity. Replace interconnect cable if necessary.
2. Disconnect the interconnect cable from the CSAFE connector and attach to the proper position on the upper PCA.3.
3. Replace the upper and lower software of the 5.17 elliptical with the most current versions.4.
4. If one of the PCAs is found to have software version 1.01, replace it with the most current software version.
5. Disconnect all components from the upper and lower PCA leaving the data cable connecting between the upper and lower PCAs and the AC power going to the lower PCA. If the unit shows any error other than the error 3x, reconnect components one at a time. Reset power between each newly connected component until the error 3x reappears. Whichever component was last connected when the error 3x reappears, is the cause for the error. Replace the faulty component.
6. Test unit with a known good lower PCA. Replace the lower PCA if necessary.
7. Test unit with a known good upper PCA. Replace the upper PCA if necessary.

Precor Error Code 30 31 32 33

I HAVE A TREADMILL AND I HAVE ERR1 WHEN I SWICH IT ON. DO YOU HAVE ANY SUGGESTIONS?

Usual cause is roller bearings. Try to oil them they are probably rusty at worst you will have to replace roller. But this is as very good machine. Good luck

Usually wax build up on rollers. Check for lumps on track at rollers.

Precor Error 45, Lift Moving in Wrong Direction Probable Cause 1. Lift motor hysteresis. 2. Lower PCA is bad. Corrective Action 1. The error would usually occur when the lift was already in motion (usually downward) when a lift command in the opposite direction (upward) was made. Some lift motors used in production exhibited a very long turnaround time and the lift motor would still be moving in the original commanded direction while the control system was trying to move the lift in the opposite commanded direction. If the error continues to re-occur, replace the lift motor. 2. It is a rare condition, however if the lift moves in the opposite direction commanded, replace the lower PCA. Precor Error Code 45