ProForm Home Gym PFEL28010 User Manual

Patent Pending  
Model No. PFEL28010  
Serial No.  
USER'S MANUAL  
Serial  
Number  
Decal  
QUESTIONS?  
If you have questions, or if  
there are missing or damaged  
parts, we will guarantee com-  
plete satisfaction through direct  
assistance from our factory.  
TO AVOID DELAYS, PLEASE  
CALL DIRECT TO OUR TOLL-  
FREE CUSTOMER HOT LINE.  
The trained technicians on our  
customer hot line will provide  
immediate assistance, free of  
charge.  
CUSTOMER HOT LINE:  
1-800-999-3756  
Mon.–Fri., 6 a.m.–6 p.m. MST  
CAUTION  
Visit our website at  
Read all precautions and  
instructions in this manual  
before using this equipment.  
Keep this manual for future  
reference.  
new products, prizes,  
fitness tips, and much more!  
 
IMPORTANT PRECAUTIONS  
WARNING:  
To reduce the risk of serious injury, read the following important precau-  
tions before using the elliptical.  
1. Read all instructions in this manual before  
using the elliptical.  
8. Wear appropriate clothing when using the  
elliptical. Always wear athletic shoes for foot  
protection.  
2. Use the elliptical only as described in this  
manual.  
9. When mounting and dismounting the ellipti-  
cal, always hold the handlebars or the T-  
handle and step onto and off the pedal that  
is in the lowest position.  
3. It is the responsibility of the owner to  
ensure that all users of the elliptical are ade-  
quately informed of all precautions.  
10. Each time you stop exercising on the  
elliptical, allow the pedals to come to  
a complete stop before dismounting.  
4. Place the elliptical on a level surface, with a  
mat beneath it to protect the floor or carpet.  
Keep the elliptical indoors, away from mois-  
ture and dust.  
11. Always keep your back straight when using  
the elliptical. Do not arch your back.  
5. Inspect and tighten all parts regularly.  
Replace any worn parts immediately.  
12. If you feel pain or dizziness at any time  
while exercising, stop immediately and  
begin cooling down.  
6. Keep children under the age of 12 and pets  
away from the elliptical at all times.  
13. The elliptical is intended for in-home use  
only. Do not use the elliptical in a commer-  
cial, rental, or institutional setting.  
7. The elliptical should not be used by persons  
weighing more than 250 pounds.  
WARNING:  
Before beginning this or any exercise program, consult your physician.  
This is especially important for persons over the age of 35 or persons with pre-existing health  
problems. Read all instructions before using. ICON assumes no responsibility for personal injury  
or property damage sustained by or through the use of this product.  
3
 
BEFORE YOU BEGIN  
Congratulations for selecting the PROFORM®  
545S low-impact elliptical exerciser. The 545S is an  
incredibly smooth exerciser that moves your feet in a  
natural elliptical path, minimizing the impact on your  
knees and ankles. And the unique 545S features  
adjustable resistance, upper-body and stationary han-  
dlebars, and a multi-mode exercise monitor to help  
you get the most from your exercise. Welcome to a  
whole new world of natural, elliptical-motion exercise  
from PROFORM.  
reading the manual, call our Customer Service  
Department toll-free at 1-800-999-3756, Monday  
through Friday, 6 a.m. until 6 p.m. Mountain Time  
(excluding holidays). To help us assist you, please  
note the product model number and serial number  
before calling. The model number is PFEL28010. The  
serial number can be found on a decal attached to the  
elliptical (see the front cover of this manual for the  
location of the decal).  
Before reading further, please familiarize yourself with  
the parts that are labeled in the drawing below.  
For your benefit, read this manual carefully before  
you use the elliptical. If you have questions after  
Water Bottle Holder  
(Bottle not included)  
Book Holder  
Resistance Knob  
T-Handle  
Handlebar  
Upright  
Side Shield  
FRONT  
Pedal Disk  
Pedal  
Pedal Arm  
LEFT SIDE  
BACK  
4
 
PART IDENTIFICATION CHART  
Use the chart below to identify the small parts used in  
assembly. The number in parenthesis below each part  
refers to the key number of the part, from the PART  
LIST on page 14. The number after the dash indicates  
the quantity needed for assembly. Note: Some small  
parts may have been pre-attached for shipping. If  
a part is not in the parts bag, check to see if it has  
been pre-attached.  
M4 x 19mm Flange  
Screw (9)—6  
M6 Nylon  
Locknut (55)—2  
M4 x 16mm  
Screw (16)—4  
M10 Nylon  
Locknut (29)—6  
M6 x 16mm Button  
Screw (54)—4  
M10 x 68mm Carriage Bolt (60)—2  
M10 x 75mm Carriage Bolt (47)—2  
3/4” Axle Cap (43)—4*  
5/8” Axle Cap (57)—2*  
Nylon Spacer (39)—2  
Pedal Arm Spacer (41)—2*  
* Extra parts may be included.  
5
 
ASSEMBLY  
Assembly requires two people. Place all parts of the elliptical in a cleared area and remove the packing mate-  
rials. Do not dispose of the packing materials until assembly is completed.  
Assembly requires a phillips screwdriver  
mallet  
, two adjustable wrenches  
, and a rubber  
.
1. Attach the Rear Stabilizer (33) to the Frame (1) with  
two M10 x 75mm Carriage Bolts (47) and two M10  
Nylon Locknuts (29).  
1
29  
1
33  
29  
47  
2. Hold the Console Bracket (45) near the Upright (3)  
and insert the Resistance Cable (26) down through  
2
45  
the Upright. Feed the Extension Wire (62) up through  
the Console Bracket.  
62  
26  
54  
Attach the Console Bracket (45) to the Upright (3)  
with two M6 x 16mm Button Screws (54) and two M6  
Split Washers (38). Make sure not to pinch the  
Resistance Cable (26) or the Extension Wire (62).  
54  
38  
38  
3
3. Making sure that the Reed Switch Wire (25) and the  
Resistance Cable (58) are in the indicated slot in the  
Frame (1), slide the Front Stabilizer (34) into the Frame.  
Do not allow the Wire or the Cable to get pinched.  
29  
3
3
29  
While a second person holds the Upright (3) near the  
Frame (1), connect the Reed Switch Wire (25) to the  
Extension Wire (62). Next, connect the Resistance  
Cable (26) to the Lower Cable (58) in the following way:  
62  
25  
26  
58  
• Refer to drawing A. Pull up on the metal bracket,  
and insert the tip of the Resistance Cable (26) into  
the wire clip on the Lower Cable (58) as shown.  
34  
• Refer to drawing B. Firmly pull the Resistance  
Cable (26) and slide it into the metal bracket on the  
Lower Cable (58) as shown.  
Slot  
1
60  
C
• Refer to drawing C. Using pliers, squeeze the prongs  
on the upper end of the metal bracket together.  
A
B
Pull any slack Resistance Cable (26) out of the top of  
the Upright (3). Attach the Upright to the Front  
Stabilizer (34) with two M10 Nylon Locknuts (29).  
Attach the Upright to the Frame (1) with two M10 x  
68mm Carriage Bolts (60) and two M10 Nylon  
Locknuts (29).  
Metal  
Bracket  
Metal  
Bracket  
26  
26  
58  
58  
6
 
4. While a second person holds the Console (6) near  
the Console Bracket (45), connect the Extension Wire  
(62) to the console wire. Make sure the slack  
4
50  
Resistance Cable (26) is pulled out of the Upright (3).  
6
Console  
Wire  
Attach the Console (6) to the Console Bracket (45)  
with four M4 x 16mm Screws (16). Push the  
Resistance Control Knob (50) onto the Resistance  
Control (26).  
62  
26  
45  
3
16  
5. Make sure that there are two Pivot Bushings (56) in  
each Handlebar (8) and in the Upright (3).  
5
Tap a 5/8” Axle Cap onto one end of the Pivot Axle  
(2). Apply a thin film of the included grease to the  
Pivot Axle.  
57  
8
Insert the Pivot Axle (2) through one of the Handlebars  
(8) and the Upright (3).  
56  
Grease  
2
56  
56  
3
6. Slide the other Handlebar (8) onto the Pivot Axle (2).  
Secure the Handlebars to the Upright (3) by tapping a  
5/8” Axle Cap (57) onto the end of the Pivot Axle.  
6
3
8
2
56  
57  
56  
7
 
7. Attach the T-handle (10) to the Upright (3) with two  
M6 x 16mm Button Screws (54) and two M6 Nylon  
Locknuts (55).  
7
54  
63  
3
10  
63  
55  
12  
8. Make sure that there are four Pedal Arm Bushings  
(11) in each Pedal Arm (12).  
8
31  
11  
Identify the Left Pedal (31), which has an “L” molded  
into its bottom surface. Attach the Left Pedal to one of  
the Pedal Arms (12) using three M4 x 19mm Flange  
Screws (9).  
Attach the Right Pedal (not shown) in the same way.  
11  
9
9. Apply a thin film of grease to the left Handlebar (8)  
and the Crank Arm (59) in the indicated locations.  
9
8
Grease  
59  
Slide a Nylon Spacer (39) onto the Handlebar (8) and  
a Pedal Arm Spacer (41) onto the Crank Arm (59).  
Next, slide the Pedal Arm (12) with the Left Pedal  
(31) onto the Handlebar and the Crank Arm. Secure  
the Pedal Arm by tapping one 3/4” Axle Cap (43) onto  
the Handlebar and another one onto the Crank Arm.  
Grease  
39  
43  
31  
12  
Attach the other Pedal Arm (not shown) to the right  
side of the elliptical in the same way.  
43  
41  
10. The Console (6) requires two “AA” batteries (not  
included). Alkaline batteries are recommended.  
10  
6
To install batteries, first locate the battery clip under  
the Console (6). Insert two batteries into the battery  
clip as shown. Make sure that the batteries are  
turned so the negative ends of the batteries  
(marked “–”) are touching the springs in the  
battery clip.  
Batteries  
Battery  
Clip  
11. Make sure that all parts of the elliptical are properly tightened. Place a mat under the elliptical to protect  
the floor or carpet from damage.  
8
 
HOW TO USE THE ELLIPTICAL  
HOW TO EXERCISE ON THE ELLIPTICAL  
HOW TO ADJUST THE RESISTANCE OF THE  
PEDALS  
To mount the elliptical, firmly hold the handlebars or  
the T-handle and carefully step onto the pedal that is  
in the lowest position. Next, step onto the other pedal.  
Push the pedals until they begin to move with a con-  
tinuous motion. Note: The pedal disks can turn in  
either direction; it is recommended that you turn  
the pedal disks in the direction shown below;  
however, to give variety to your exercise, you may  
choose to turn the pedal disks in the opposite  
direction.  
As you exercise,  
you can adjust  
the resistance of  
the pedals with  
the resistance  
knob on the  
console. To  
increase the  
resistance,  
Resistance Knob  
turn the knob  
clockwise; to  
decrease the  
resistance, turn the knob counterclockwise.  
Pedal Disk  
Pedal  
To dismount the elliptical, allow the pedals to come to  
a complete stop. CAUTION: The elliptical does not  
have a freewheel; the pedals will continue to  
move until the flywheel stops. When the pedals are  
stationary, step off the highest pedal first. Then, step  
off the lowest pedal.  
9
 
DESCRIPTION OF THE CONSOLE  
HOW TO OPERATE THE CONSOLE  
The console is designed to help you get the most  
from your workouts. As you exercise, you can watch  
your progress around the LED track, while the  
display provides continuous exercise feedback.  
The six modes of the display are described below.  
If there is a thin sheet of clear plastic on the face of  
the console, remove it.  
1. To turn on the power, press the on/reset button or  
simply begin exercising. When the power is turned  
on, one LED indicator will light in the LED track,  
and the entire display will appear for two seconds.  
The console will then be ready for operation.  
2. Select one of the five modes:  
Scan mode—  
When the power  
is turned on, the  
scan mode will  
automatically be  
LED Track  
selected. One  
Mode Indicators  
mode indicator  
will show that the  
scan mode is selected, and a flashing mode indica-  
tor will show which mode is currently displayed.  
Note: If a different mode is selected, you can  
select the scan mode again by repeatedly pressing  
the mode button.  
Speed—This mode displays your current exercise  
speed, in miles per hour.  
Speed, time,  
distance, laps,  
or calorie mode—  
To select one of  
these modes for  
Time—This mode displays the length of time you  
have exercised. Note: If you stop exercising, the time  
mode will pause until you resume.  
continuous  
display, press the  
Distance—This mode displays the total distance you  
have completed, in miles.  
mode button repeatedly. The mode indicators will  
show which mode is selected. (Make sure that the  
scan mode is not selected.)  
Laps—This mode displays the number of 1/4-mile  
laps you have completed around the LED track.  
3. The LED track represents a distance of 1/4 mile. As  
you exercise, the indicators around the track will  
light one at a time until you have completed 1/4  
mile. A new lap will then begin.  
Calorie—This mode displays the approximate number  
of Calories you have burned.  
Scan—This mode displays the speed, time, distance,  
laps, and calorie modes, for 5 seconds each, in a  
repeating cycle.  
4. To reset the display, press the on/reset button.  
5. To turn off the power, simply wait for about four  
minutes. Note: The console has an “auto-off”  
feature. If the pedals are not moved and the  
console buttons are not pressed for four  
minutes, the power will turn off automatically  
in order to conserve the batteries.  
BATTERY INSTALLATION  
Before the console can be operated, two “AA” batter-  
ies must be installed. If you have not installed batter-  
ies, see assembly step 10 on page 8.  
10  
 
MAINTENANCE  
Inspect and tighten all parts of the elliptical  
regularly. Replace any worn parts immediately.  
CONSOLE TROUBLE-SHOOTING  
If the console does not function properly, the batteries  
should be replaced. To replace the batteries, refer to  
assembly step 10 on page 8.  
The elliptical can be wiped clean with a soft cloth and  
mild detergent. Do not use abrasives or solvents.  
To prevent damage to the console, keep liquids away  
from the console. Use only a sealable water bottle in  
the console.  
STORAGE  
When storing the elliptical, remove the batteries from  
the console. Keep the elliptical in a clean, dry loca-  
tion, away from moisture and dust.  
11  
 
CONDITIONING GUIDELINES  
The following guidelines will help you to plan your  
exercise program. Remember that proper nutrition  
and adequate rest are essential for successful results.  
gy. Only after the first few minutes of exercise does  
your body begin to use stored fat calories for energy.  
If your goal is to burn fat, adjust the intensity of your  
exercise until your heart rate is near the smallest  
number in your training zone as you exercise.  
WARNING:  
Before beginning this  
For maximum fat burning, adjust the intensity of your  
exercise until your heart rate is near the middle num-  
ber in your training zone as you exercise.  
or any exercise program, consult your physi-  
cian. This is especially important for persons  
over the age of 35 or persons with pre-exist-  
ing health problems.  
Aerobic Exercise  
If your goal is to strengthen your cardiovascular sys-  
tem, your exercise must be “aerobic.” Aerobic exer-  
cise is activity that requires large amounts of oxygen  
for prolonged periods of time. This increases the  
demand on the heart to pump blood to the muscles,  
and on the lungs to oxygenate the blood. For aerobic  
exercise, adjust the intensity of your exercise until  
your heart rate is near the largest number in your  
training zone.  
EXERCISE INTENSITY  
Whether your goal is to burn fat or to strengthen your  
cardiovascular system, the key to achieving the  
desired results is to exercise with the proper intensity.  
The proper intensity level can be found by using your  
heart rate as a guide. The chart below shows recom-  
mended heart rates for fat burning, maximum fat  
burning, and cardiovascular (aerobic) exercise.  
HOW TO MEASURE YOUR HEART RATE  
To measure your  
heart rate, first  
exercise for at  
least four minutes.  
Then, stop exercis-  
ing and place two  
fingers on your  
wrist as shown.  
Take a six-second  
heartbeat count, and multiply the result by 10 to find  
your heart rate. For example, if your six-second heart-  
beat count is 14, your heart rate is 140 beats per  
minute. (A six-second count is used because your  
heart rate will drop rapidly when you stop exercising.)  
To find the proper heart rate for you, first find your age  
at the bottom of the chart (ages are rounded off to the  
nearest ten years). Next, find the three numbers  
above your age. The three numbers are your “training  
zone.” The smallest number is the recommended  
heart rate for fat burning; the middle number is the  
heart rate for maximum fat burning; the largest  
number is the heart rate for aerobic exercise.  
WORKOUT GUIDELINES  
Each workout should include the following three  
important parts:  
A warm-up, consisting of 5 to 10 minutes of stretch-  
ing and light exercise. (See page 13.) A proper warm-  
up increases your body temperature, heart rate, and  
circulation in preparation for exercise.  
Burning Fat  
To burn fat effectively, you must exercise at a rela-  
tively low intensity level for a sustained period of time.  
During the first few minutes of exercise, your body  
uses easily accessible carbohydrate calories for ener-  
12  
 
Training zone exercise, consisting of 20 to 30  
minutes of exercising with your heart rate in your  
training zone. (During the first few weeks of your  
exercise program, do not keep your heart rate in  
your training zone for longer than 20 minutes.)  
EXERCISE FREQUENCY  
To maintain or improve your condition, plan three work-  
outs each week, with at least one day of rest between  
workouts. After a few months of regular exercise, you  
may plan up to five workouts each week, if desired.  
CAUTION: Be sure to progress at your own pace  
and avoid overdoing it. Incorrect or excessive  
training may result in injury to your health.  
A cool-down, with 5 to 10 minutes of stretching.  
This will increase the flexibility of your muscles  
and will help to prevent post-exercise problems.  
Remember, the key to success is make exercise a  
regular and enjoyable part of your everyday life.  
SUGGESTED STRETCHES  
The correct form for several basic stretches is shown at the  
right. Move slowly as you stretch—never bounce.  
1
1. Toe Touch Stretch  
Stand with your knees bent slightly and slowly bend forward  
from your hips. Allow your back and shoulders to relax as you  
reach down toward your toes as far as possible. Hold for 15  
counts, then relax. Repeat 3 times. Stretches: Hamstrings, back  
of knees, and back.  
2
2. Hamstring Stretch  
Sit with one leg extended. Bring the sole of the opposite foot  
toward you and rest it against the inner thigh of your extended  
leg. Reach toward your toes as far as possible. Hold for 15  
counts, then relax. Repeat 3 times for each leg. Stretches:  
Hamstrings, lower back, and groin.  
3. Calf/Achilles Stretch  
3
With one leg in front of the other, reach forward and place your  
hands against a wall. Keep your back leg straight and your back  
foot flat on the floor. Bend your front leg, lean forward and move  
your hips toward the wall. Hold for 15 counts, then relax.  
Repeat 3 times for each leg. To cause further stretching of the  
achilles tendons, bend your back leg as well. Stretches: Calves,  
achilles tendons, and ankles.  
4
4. Quadriceps Stretch  
With one hand against a wall for balance, reach back and grasp  
one foot with your other hand. Bring your heel as close to your  
buttocks as possible. Hold for 15 counts, then relax. Repeat 3  
times for each leg. Stretches: Quadriceps and hip muscles.  
13  
 
PART LIST—Model No. PFEL28010  
R0601A  
Key  
No.  
Key  
No.  
Qty.  
Description  
Qty.  
Description  
1
2
3
4
5
6
7
8
1
1
1
1
1
1
2
2
6
1
8
2
10  
1
1
11  
2
2
2
2
1
2
1
1
1
1
2
1
6
1
1
1
1
1
2
Frame  
Pivot Axle  
Upright  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
#
2
2
2
2
1
2*  
1
4*  
1
1
2
2
1
1
1
4
1
2
4
2
6
2*  
1
2
2
1
1
2
1
1
1
1
2
1
1
Pulley Bearing  
Pedal Disk  
M6 Split Washer  
Nylon Spacer  
Side Shield Bracket  
Pedal Arm Spacer  
Right Pedal  
Right Side Shield  
Left Side Shield  
Console  
Foam Handlebar Grip  
Handlebar  
M4 x 19mm Flange Screw  
T-handle  
Pedal Arm Bushing  
Pedal Arm  
M5 x 16mm Button Screw  
Resistance Strap  
Strap Buckle  
M4 x 16mm Screw  
M6 Nut  
Adjustment Bracket  
Eyebolt  
M8 Nylon Jam Nut  
Flywheel Axle  
Flywheel Bearing  
Flywheel  
3/4” Axle Cap  
9
M4 x 16mm Flat Screw  
Console Bracket  
Front Stabilizer Endcap  
M10 x 75mm Carriage Bolt  
Cable Clamp Assembly  
M4 x 64mm Button Screw  
Resistance Control Knob  
M5 x 28mm Button Screw  
Return Spring  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
8.5 Washer  
M6 x 16mm Button Screw  
M6 Nylon Locknut  
Pivot Bushing  
5/8” Axle Cap  
Lower Cable  
Magnet  
Crank Arm  
Reed Switch/Wire  
Resistance Control/Cable  
Rear Stabilizer Endcap  
Tension Spring  
M10 Nylon Locknut  
Belt  
M10 x 68mm Carriage Bolt  
Reed Switch Clamp  
Extension Wire  
T-handle Endcap  
Plastic Washer  
Crank Arm Plastic Spacer  
Grease Packet  
User’s Manual  
Left Pedal  
Pulley w/Shaft  
Rear Stabilizer  
Front Stabilizer  
5/16” Zinc Bolt  
#
#
#
#
Side Shield Decal  
Warning Decal  
Hardware Kit  
Note: “#” indicates a non-illustrated part. “ ” indicates that an extra part may be included. Specifications are  
*
subject to change without notice. See the back cover of this manual for information about ordering replacement  
parts.  
14  
 
EXPLODED DRAWING—Model No. PFEL28010  
R0601A  
15  
 
HOW TO ORDER REPLACEMENT PARTS  
To order replacement parts, simply call our Customer Service Department toll-free at 1-800-999-3756, Monday  
through Friday, 6 a.m. until 6 p.m. Mountain Time (excluding holidays). To help us assist you, please be pre-  
pared to give the following information when calling:  
• The MODEL NUMBER of the product (PFEL28010)  
• The NAME of the product (PROFORM® 545S elliptical)  
• The SERIAL NUMBER of the product (see the front cover of this manual)  
• The KEY NUMBER and DESCRIPTION of the part(s) from page 14 of this manual.  
PROFORM is a registered trademark of ICON Health & Fitness, Inc.  
LIMITED WARRANTY  
ICON Health & Fitness, Inc. (ICON) warrants this product to be free from defects in workmanship and  
material, under normal use and service conditions, for a period of ninety (90) days from the date of pur-  
chase. This warranty extends only to the original purchaser. ICON's obligation under this warranty is lim-  
ited to replacing or repairing, at ICON's option, the product at one of its authorized service centers. All  
products for which warranty claim is made must be received by ICON at one of its authorized service cen-  
ters with all freight and other transportation charges prepaid, accompanied by sufficient proof of purchase.  
All returns must be pre-authorized by ICON. This warranty does not extend to any product or damage to  
a product caused by or attributable to freight damage, abuse, misuse, improper or abnormal usage or  
repairs not provided by an ICON authorized service center, to products used for commercial or rental pur-  
poses, or to products used as store displays. No other warranty beyond that specifically set forth above  
is authorized by ICON.  
ICON is not responsible or liable for indirect, special or consequential damages arising out of or in con-  
nection with the use or performance of the product or damages with respect to any economic loss, loss  
of property, loss of revenues or profits, loss of enjoyment or use, costs of removal, installation or other  
consequential damages of whatsoever nature. Some states do not allow the exclusion or limitation of inci-  
dental or consequential damages. Accordingly, the above limitation may not apply to you.  
The warranty extended hereunder is in lieu of any and all other warranties and any implied warranties of  
merchantability or fitness for a particular purpose is limited in its scope and duration to the terms set forth  
herein. Some states do not allow limitations on how long an implied warranty lasts. Accordingly, the above  
limitation may not apply to you.  
This warranty gives you specific legal rights. You may also have other rights which vary from state to state.  
ICON HEALTH & FITNESS, INC., 1500 S. 1000 W., LOGAN, UT 84321-9813  
Part No. 175988 R0601A  
Printed in China © 2001 ICON Health & Fitness, Inc.  
 

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