Patent Pending
USER'S MANUAL
CAUTION
Read all precautions and
instructions in this manual
before using this equipment.
Keep this manual for future
reference.
Model No. 831.285270
Serial No.
Serial
Number
Decal
SEARS, ROEBUCK AND CO.,
HOFFMAN ESTATES, IL 60179
Write the serial number in the
space above for future reference.
®
Visit our website at
www.proform.com
new products, prizes,
fitness tips, and much more!
2
TABLE OF CONTENTS
IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PART IDENTIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HOW TO USE THE ELLIPTICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
CONDITIONING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
PART LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
EXPLODED DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
HOW TO ORDER REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
FULL 90-DAY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
3
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.
2. Use the elliptical only as described in this
manual.
3. It is the responsibility of the owner to
ensure that all users of the elliptical are adequately informed of all precautions.
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 moisture and dust.
5. Inspect and tighten all parts regularly.
Replace any worn parts immediately.
6. Keep children under the age of 12 and pets
away from the elliptical at all times.
7. The elliptical should not be used by persons
weighing more than 250 pounds.
8. Wear appropriate clothing when using the
elliptical. Always wear athletic shoes for foot
protection.
9. When mounting and dismounting the elliptical, always hold the handlebars or the Thandle and step onto and off the pedal that
is in the lowest position.
10. Each time you stop exercising on the
elliptical, allow the pedals to come to
a complete stop before dismounting.
11. Always keep your back straight when using
the elliptical. Do not arch your back.
12. If you feel pain or dizziness at any time
while exercising, stop immediately and
begin cooling down.
13. The elliptical is intended for in-home use
only. Do not use the elliptical in a commercial, rental, or institutional setting.
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. SEARS assumes no responsibility for personal injury
or property damage sustained by or through the use of this product.
4
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 handlebars, 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.
For your benefit, read this manual carefully before
you use the elliptical. If you have additional ques-
tions, please call our toll-free HELPLINE at 1-800736-6879, Monday through Saturday, 7 a.m. until 7
p.m. Central Time (excluding holidays). To help us
assist you, please note the product model number
and serial number before calling. The model number
is 831.285270. The serial number can be found on a
decal attached to the elliptical trainer (see the front
cover of this manual for the location of the decal).
Before reading further, please look at the drawing
below and familiarize yourself with the parts that are
labeled.
Resistance Knob
FRONT
BACK
LEFT SIDE
Pedal Arm
Pedal Disk
Side Shield
Pedal
Book Holder
Upright
Water Bottle Holder
(Bottle not included)
T-Handle
Handlebar
5
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.
* Extra parts may be included.
M4 x 19mm Flange
Screw (9)—6
M10 x 75mm Carriage Bolt (47)—2
M4 x 16mm
Screw (16)—4
M6 x 16mm Button
Screw (54)—4
M6 Nylon
Locknut (55)—2
M10 x 68mm Carriage Bolt (60)—2
M10 Nylon
Locknut (29)—6
Nylon Spacer (39)—2
3/4” Axle Cap (43)—4*
Pedal Arm Spacer (41)—2*
5/8” Axle Cap (57)—2*
6
1. Attach the Rear Stabilizer (33) to the Frame (1) with
two M10 x 75mm Carriage Bolts (47) and two M10
Nylon Locknuts (29).
2. Hold the Console Bracket (45) near the Upright (3)
and insert the Resistance Cable (26) down through
the Upright. Feed the Extension Wire (62) up through
the Console Bracket.
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).
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 , two adjustable wrenches , and a rubber
mallet .
2
1
47
33
1
29
29
3
45
62
38
54
54
26
38
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.
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:
• 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.
• Refer to drawing B. Firmly pull the Resistance
Cable (26) and slide it into the metal bracket on the
Lower Cable (58) as shown.
• Refer to drawing C. Using pliers, squeeze the prongs
on the upper end of the metal bracket together.
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).
29
3
62
25
26
58
29
1
3
34
Slot
60
A
B
C
58
26
26
Metal
Bracket
Metal
Bracket
58
7
5. Make sure that there are two Pivot Bushings (56) in
each Handlebar (8) and in the Upright (3).
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.
Insert the Pivot Axle (2) through one of the Handlebars
(8) and the Upright (3).
5
2
8
57
56
56
56
3
Grease
6
8
3
56
56
57
2
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.
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
Resistance Cable (26) is pulled out of the Upright (3).
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).
4
6
50
26
45
62
16
Console
Wire
3
8
10. The Console (6) requires two “AA” batteries (not
included). Alkaline batteries are recommended.
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.
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.
6
10
7
8
9
55
63
31
12
11
11
9
43
43
12
39
31
Grease
Grease
8
59
41
63
54
10
3
Batteries
Battery
Clip
7. Attach the T-handle (10) to the Upright (3) with two
M6 x 16mm Button Screws (54) and two M6 Nylon
Locknuts (55).
8. Make sure that there are four Pedal Arm Bushings
(11) in each Pedal Arm (12).
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.
9. Apply a thin film of grease to the left Handlebar (8)
and the Crank Arm (59) in the indicated locations.
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.
Attach the other Pedal Arm (not shown) to the right
side of the elliptical in the same way.
9
HOW TO USE THE ELLIPTICAL
HOW TO EXERCISE ON THE ELLIPTICAL
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 continuous 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.
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.
HOW TO ADJUST THE RESISTANCE OF THE
PEDALS
As you exercise,
you can adjust
the resistance of
the pedals with
the resistance
knob on the
console. To
increase the
resistance,
turn the knob
clockwise; to
decrease the
resistance, turn the knob counterclockwise.
Pedal
Pedal Disk
Resistance Knob
10
DESCRIPTION OF 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.
Speed—This mode displays your current exercise
speed, in miles per hour.
Time—This mode displays the length of time you
have exercised. Note: If you stop exercising, the time
mode will pause until you resume.
Distance—This mode displays the total distance you
have completed, in miles.
Laps—This mode displays the number of 1/4-mile
laps you have completed around the LED track.
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.
BATTERY INSTALLATION
Before the console can be operated, two “AA” batteries must be installed. If you have not installed batteries, see assembly step 10 on page 8.
HOW TO OPERATE THE CONSOLE
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
selected. One
mode indicator
will show that the
scan mode is selected, and a flashing mode indicator 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, time,
distance, laps,
or calorie mode—
To select one of
these modes for
continuous
display, press the
mode button repeatedly. The mode indicators will
show which mode is selected. (Make sure that the
scan mode is not selected.)
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. Anew lap will then begin.
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.
Mode Indicators
LED Track
11
MAINTENANCE
Inspect and tighten all parts of the elliptical
regularly. Replace any worn parts immediately.
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.
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.
STORAGE
When storing the elliptical, remove the batteries from
the console. Keep the elliptical in a clean, dry location, away from moisture and dust.
12
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.
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 recommended heart rates for fat burning, maximum fat
burning, and cardiovascular (aerobic) exercise.
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.
Burning Fat
To burn fat effectively, you must exercise at a relatively 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-
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.
For maximum fat burning, adjust the intensity of your
exercise until your heart rate is near the middle number in your training zone as you exercise.
Aerobic Exercise
If your goal is to strengthen your cardiovascular system, your exercise must be “aerobic.” Aerobic exercise 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.
HOW TO MEASURE YOUR HEART RATE
To measure your
heart rate, first
exercise for at
least four minutes.
Then, stop exercising 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 heartbeat 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.)
WORKOUT GUIDELINES
Each workout should include the following three
important parts:
A warm-up, consisting of 5 to 10 minutes of stretching and light exercise. (See page 13.) Aproper warmup increases your body temperature, heart rate, and
circulation in preparation for exercise.
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.
13
SUGGESTED STRETCHES
The correct form for several basic stretches is shown at the
right. Move slowly as you stretch—never bounce.
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. 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
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. 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.
1
2
3
4
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.)
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.
EXERCISE FREQUENCY
To maintain or improve your condition, plan three workouts 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.
Remember, the key to success is make exercise a
regular and enjoyable part of your everyday life.
14
PART LIST—Model No. 831.285270 R0601A
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.
Key
No. Qty. Description
1 1 Frame
2 1 Pivot Axle
3 1 Upright
4 1 Right Side Shield
5 1 Left Side Shield
6 1 Console
7 2 Foam Handlebar Grip
8 2 Handlebar
9 6 M4 x 19mm Flange Screw
10 1 T-handle
1 1 8 Pedal Arm Bushing
12 2 Pedal Arm
13 10 M5 x 16mm Button Screw
14 1 Resistance Strap
15 1 Strap Buckle
16 11 M4 x 16mm Screw
17 2 M6 Nut
18 2 Adjustment Bracket
19 2 Eyebolt
20 2 M8 Nylon Jam Nut
21 1 Flywheel Axle
22 2 Flywheel Bearing
23 1 Flywheel
24 1 Magnet
25 1 Reed Switch/Wire
26 1 Resistance Control/Cable
27 2 Rear Stabilizer Endcap
28 1 Tension Spring
29 6 M10 Nylon Locknut
30 1 Belt
31 1 Left Pedal
32 1 Pulley w/Shaft
33 1 Rear Stabilizer
34 1 Front Stabilizer
35 2 5/16” Zinc Bolt
Key
No. Qty. Description
36 2 Pulley Bearing
37 2 Pedal Disk
38 2 M6 Split Washer
39 2 Nylon Spacer
40 1 Side Shield Bracket
41 2* Pedal Arm Spacer
42 1 Right Pedal
43 4* 3/4” Axle Cap
44 1 M4 x 16mm Flat Screw
45 1 Console Bracket
46 2 Front Stabilizer Endcap
47 2 M10 x 75mm Carriage Bolt
48 1 Cable Clamp Assembly
49 1 M4 x 64mm Button Screw
50 1 Resistance Control Knob
51 4 M5 x 28mm Button Screw
52 1 Return Spring
53 2 8.5 Washer
54 4 M6 x 16mm Button Screw
55 2 M6 Nylon Locknut
56 6 Pivot Bushing
57 2* 5/8” Axle Cap
58 1 Lower Cable
59 2 Crank Arm
60 2 M10 x 68mm Carriage Bolt
61 1 Reed Switch Clamp
62 1 Extension Wire
63 2 T-handle Endcap
64 1 Plastic Washer
65 1 Crank Arm Plastic Spacer
# 1 Grease Packet
# 1 User’s Manual
# 2 Side Shield Decal
# 1 Warning Decal
# 1 Hardware Kit
EXPLODED DRAWING—Model No. 831.285270 R0601A
15
50
13
49
4
54
38
51
63
57
13
51
13
16
26
56
10
56
54
56
63
55
56
42
43
16
11
8
39
3
16
14
29
11
43
12
41
65
13
40
48
35
1
52
16
37
36
61
25
59
29
36
60
60
62
30
13
9
19
20
17
2
56
18
46
53
34
21
17
22
22
18
23
24
53
19
20
28
58
46
8
64
59
15
27
33
5
29
44
41
11
16
47
27
32
37
35
13
11
6
45
16
7
56
57
31
39
11
43
12
9
43
Part No. 175921 R0601A Printed in China © 2001 Sears, Roebuck and Co.
The model number and serial number of your PROFORM®545S
are listed on a decal attached to the frame. See the front cover of
this manual to find the location of the decal.
All replacement parts are available for immediate purchase or
special order when you visit your nearest SEARS Service Center.
To request service or to order parts by telephone, call the toll-free
numbers listed at the left.
When requesting help or service, or ordering parts, please be prepared to provide the following information:
• The MODEL NUMBER of the product (831.285270)
• 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.
Model No. 831.285270
QUESTIONS?
If you find that:
• you need help assembling or
operating the PROFORM®545S
• a part is missing
• or you need to schedule repair
service
call our toll-free HELPLINE
1-800-736-6879
Monday–Saturday, 7 am–7 pm
Central Time (excluding holidays)
REPLACEMENT
PARTS
If parts become worn and need to
be replaced, call the following
toll-free number
1-800-FON-PART
(1-800-366-7278)
FULL 90 DAY WARRANTY
For 90 days from the date of purchase, if failure occurs due to defect in material or workmanship in this
SEARS ELLIPTICAL EXERCISER, contact the nearest SEARS Service Center throughout the United
States and SEARS will repair or replace the ELLIPTICAL EXERCISER, free of charge.
This warranty does not apply when the ELLIPTICAL EXERCISER is used commercially or for rental
purposes.
This warranty gives you specific legal rights, and you may also have other rights which vary from state
to state.
SEARS, ROEBUCK AND CO., DEPT. 817WA, HOFFMAN ESTATES, IL 60179
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