Patent Pending
Model No. 831.285960
Serial No.
USER’S MANUAL
Write the serial number in the
space above for future reference.
Serial
Number
Decal
SEARS, ROEBUCK AND CO.,
HOFFMAN ESTATES, IL 60179
CAUTION
Visit our website at
Read all precautions and
instructions in this manual
before using this equipment.
Keep this manual for future
reference.
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fitness tips, and much more!
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IMPORTANT PRECAUTIONS
WARNING:
To reduce the risk of serious injury, read the following important precau-
tions before using the PROFORM® 545E elliptical trainer.
1. Read all instructions in this manual before
using the elliptical trainer.
8. Wear appropriate clothing when using the
elliptical trainer. Always wear athletic shoes
for foot protection.
2. Use the elliptical trainer only as described in
this manual.
9. When mounting and dismounting the ellipti-
cal trainer, 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 trainer
are adequately informed of all precautions.
10. Each time you stop exercising on the
elliptical trainer, allow the pedals to come to
a complete stop before dismounting.
4. Place the elliptical trainer on a level surface,
with a mat beneath it to protect the floor or
carpet. Keep the elliptical trainer indoors,
away from moisture and dust.
11. Always keep your back straight when using
the elliptical trainer. 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 trainer at all times.
13. The elliptical trainer is intended for in-home
use only. Do not use the elliptical trainer in a
commercial, rental, or institutional setting.
7. The elliptical trainer 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. SEARS assumes no responsibility for personal injury
or property damage sustained by or through the use of this product.
3
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BEFORE YOU BEGIN
Congratulations for selecting the PROFORM® 545E
elliptical trainer. The 545E 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 545E 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 nat-
ural, elliptical-motion exercise from PROFORM.
questions, please call our toll-free HELPLINE at 1-
800-736-6879, 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 831.285960. 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.
For your benefit, read this manual carefully before
you use the elliptical trainer. If you have additional
Water Bottle Holder
(Bottle not included)
Book Holder
Resistance Knob
T-Handle
Handlebar
Upright
FRONT
Side Shield
Pedal Disk
Pedal
Pedal Arm
LEFT SIDE
BACK
4
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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 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 16mm Round
Head Screw (38)—4
M4 x 19mm Round
Head Screw (16)—6
M6 x 16mm Screw (54)—2
M6 Black Nylon Locknut (55)—2
M10 Nylon Locknut (29)—4
Weld Spacer (49)—2
3/4” Axle Cap (43)—4*
5/8” Axle Cap (57)—2*
Pedal Arm Bushing (42)—4
Rear Pedal Arm Bushing (11)—4
Pedal Arm Spacer (41)—3*
Handlebar Spacer (39)—2
* Extra parts may be included.
5
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ASSEMBLY
Assembly requires two people. Place all parts of the elliptical trainer in a cleared area and remove the packing
materials. Do not dispose of the packing materials until assembly is completed.
Assembly requires that you have a phillips screwdriver
rubber mallet , and a pair pliers
, two adjustable wrenches
, a
.
1. While another person holds the Console (6) near the
Upright (3), insert the Resistance Cable (26) down
through the Upright.
1
6
26
3
2. While another person holds the Upright (3) near the
Frame (1) as shown, connect the Extension Wire
(63) to the Sensor Wire (25).
2
29
3
Next, connect the Resistance Cable (26) to the
Lower Cable (64) 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 (64) as shown.
• Refer to drawing B. Firmly pull the Resistance
Cable (26) and slide it into the metal bracket on the
Lower Cable (64) as shown.
26
64
63
1
• Refer to drawing C. Using pliers, squeeze the
prongs on the upper end of the metal bracket
together.
25
Welded
Bolts
Slide the Upright (3) onto the welded bolts on the
Frame (1). Make sure that the Resistance Cable
(26) doesn’t become caught on the Frame (1) or
the Upright (3). Be careful to avoid pinching the
Resistance Cable and the Sensor Wire (25)
between the the Frame and the Upright. Tighten
an M10 Nylon Locknut (29) onto each welded bolt.
A
B
C
Metal
Bracket
26
26
64
26
64
64
6
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3. While another person holds the Console (6) near the
Upright (3), connect the console wire to the Extension
Wire (63).
3
50
6
Console
Wire
Make sure the slack Resistance Cable (26) is pulled
up out of the Upright (3). Feed the slack Extension
Wire (63) down into the Upright (3). Push the excess
Resistance Cable into the Console (6). Attach the
Console to the Upright with four M4 x 16mm Round
Head Screws (38). Be careful to avoid pinching the
Resistance Cable and the Extension Wire.
63
26
Press the Resistance Knob (50) onto the Resistance
Cable (26).
3
38
3. Find the Left Pedal (31), which has a ridge on the
right side. Attach the Left Pedal to one of the Pedal
Arms (12) with three M4 x 19mm Round Head
Screws (16) as shown.
3
Ridge
31
Repeat this step to attach the Right Pedal to the other
Pedal Arm (not shown).
12
16
4. Locate the Left Handlebar (8) (there is an “L” sticker
on the Left Handlebar for identification). Apply a thin
film of the included grease to the axle at the lower
end of the Left Handlebar.
4
62
8
12
Slide a Handlebar Spacer (39) and the Pedal Arm
(12) with the Left Pedal (31) onto the Left Handlebar
(8) as shown. Make sure that there are two Pedal
Arm Bushings (42) in the Pedal Arm. (Note: These
parts fit tightly; it may be helpful to use the rubber
mallet). Next, refer to the PART IDENTIFICATION
CHART on page 5 and identify the 3/4” Axle Caps
(43). Tap a 3/4” Axle Cap onto the Left Handlebar.
39
42
43
Grease
12
Repeat this step to attach the other Pedal Arm (12) to
the Right Handlebar (62).
31
7
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5. Slide a Weld Spacer (49) onto the left axle on the
Upright (3). Make sure that the open side of the Weld
Spacer is facing the Upright.
5
Apply a thin film of the included grease to the axles
and crank arms in the locations indicated.
Slide a Pedal Arm Spacer (41) onto the left Crank
Arm (59). Make sure that there are two Rear Pedal
Arm Bushings (11) in the Pedal Arm (12) attached to
the Left Handlebar (8).
Grease
57
8
With the help of another person, slide the Left
Handlebar (8) onto the left axle on the Upright (3)
while sliding the left Pedal Arm (12) onto the left
Crank Arm (59). Note: These parts fit tightly; it may be
helpful to use the rubber mallet. In addition, it may be
helpful to rotate the left Crank Arm (59) to a different
position.
49
3
Grease
59
Tap a 5/8” Axle Cap (57) onto the left axle on the
Upright (3). Tap a 3/4” Axle Cap (43) onto the left
Crank Arm (59).
41
12
Repeat this step to attach the Right Handlebar and
the right Pedal Arm (not shown).
11
43
6. Attach the T-Handle (10) to the Upright (3) with two
M6 x 16mm Screws (54) and two M6 Black Nylon
Locknuts (55).
6
54
3
10
55
7. The Console (6) requires four “AA” batteries (not
included). Alkaline batteries are recommended.
7
6
To install batteries, look under the Console (6) and
locate the two Battery Covers (66)—there is one
Battery Cover on each side. Remove the Battery
Covers by sliding them in the direction shown by the
arrows on the Battery Covers. Insert two batteries into
each battery compartment; make sure that all four
batteries are turned so the negative ends (marked
“–”) are touching the springs in the battery com-
partments. Then, reattach the Battery Covers by slid-
ing them in the opposite direction.
Batteries
66
8. Make sure that all parts of the elliptical trainer are properly tightened. Place a mat under the elliptical
trainer to protect the floor or carpet from damage.
8
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HOW TO USE THE ELLIPTICAL TRAINER
HOW TO EXERCISE ON THE ELLIPTICAL TRAINER
DESCRIPTION OF THE CONSOLE
To mount the elliptical trainer, firmly hold the handle-
bars 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.
Pedal Disk
The innovative console offers a manual mode and
three personal coach pace programs. The pace pro-
grams are designed to help you achieve specific exer-
cise goals by pacing your exercise. You can choose
from a stamina-building interval program, an aerobic
program, and a special fat burning program. The con-
sole also features six modes that display instant exer-
cise feedback. The modes are described below:
Calories—This mode shows the approximate number
of calories you have burned.
Pedal
Fat Calories—This mode shows the approximate
number of fat calories you have burned (see Burning
Fat on page 12).
To dismount the elliptical trainer, allow the pedals to
come to a complete stop. CAUTION: The elliptical
trainer does not have a free wheel; 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.
Time—If you select the manual mode, this mode will
show the elapsed time. If you select one of the three
pace programs, this mode will count down the time
remaining in the program. Note: When you stop exer-
cising, the time will flash when it is displayed.
HOW TO ADJUST THE RESISTANCE OF THE
PEDALS
Distance—This mode shows your total distance, in
miles.
As you exercise,
you can adjust
the resistance of
the pedals with
the resistance
knob on the
Resistance Knob
Speed—This mode shows your exercise pace, in
miles per hour.
Scan—This mode displays the other five modes, for
seven seconds each, in a repeating cycle.
console. To
increase the
resistance,
turn the knob
clockwise; to
decrease the
resistance, turn the knob counterclockwise.
9
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HOW THE PACE PROGRAMS OPERATE
Select one of the three pace programs or the
manual mode
2
When you use a
pace program, two
columns of bars will
appear in the upper
display. The left col-
umn represents a
To select one of
the pace
programs,
repeatedly press
the program
select button. A
Indicator
Target Pace Actual Pace
target pace, and the
right column shows
1, 2, or 3 will
your actual exercise
appear in the upper display to show which pro-
gram you have selected. To select the manual
mode, press the program select button until no
number appears in the upper display. The pro-
grams will be selected in the following order: pro-
gram 1 (interval), program 2 (aerobic), program 3
(fat burn), manual mode.
pace. The target pace will change periodically during
the program; as the target pace changes, simply
adjust your pace to keep both columns at the same
height. Important: The target pace is a goal pace.
Your actual pace may be slower than the target
pace, especially during the first few months of
your exercise program. Be sure to exercise at a
pace that is comfortable for you.
Begin your workout
3
The three graphs
on the console
If you selected
the manual
show how the target
pace will change
during the
programs. During
mode, go to
step 4. If you
selected one of
the pace pro-
the Aerobic
Actual Pace
grams, two
Target Pace
program (program 2), for example, the target pace will
gradually increase during the first half of the program,
and gradually decrease during the last half of the pro-
gram. Each program will last for twenty minutes.
columns of bars
will appear in
the upper display. The left column will show a
target pace. The right column will show your
actual exercising pace. Adjust your pace until the
same number of bars appear in both columns.
The arrows on the right side of the upper display
will show whether you need to increase or
decrease your pace. Each time the target pace
changes during the program, adjust your pace to
keep both columns at the same height.
STEP-BY-STEP CONSOLE OPERATION
Before the console can be operated, batteries
must be installed. See assembly step 7 on page 8.
Follow the steps below to operate the console.
Turn on the power
Follow your progress with the six feedback
modes
1
4
To turn on the
power, press
The scan
the on/reset
mode—
button or
simply begin
Repeatedly
press the mode
Bar
exercising.
button until a
The entire dis-
bar appears
play will appear for two seconds; the console will
then be ready for use. Note: If batteries were just
installed, the power will already be on.
above the scan
symbol. When the scan mode is selected, the con-
sole will display the calories, fat calories, time,
distance, and speed modes, for seven seconds
each, in a repeating cycle.
10
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The calories,
fat calories,
If desired, press the on/reset button to reset the
lower display.
time, distance,
or speed
mode—
Repeatedly
press the
Turn off the power
5
To turn off the power, simply wait for about
six minutes. If the pedals are not turned and the
buttons are not pressed for six minutes, the
power will turn off automatically.
mode button until a bar appears below or above
the name of the desired mode. (Note: When the
time mode is selected, no bar will appear; when
the speed mode is selected, the letters MPH will
appear instead of a bar.) Make sure that there is
not a bar above the word “scan.”
MAINTENANCE
Inspect and tighten all parts of the elliptical trainer
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 7 on page 8.
The elliptical trainer 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 trainer, remove the batter-
ies from the console. Keep the elliptical trainer in a
clean, dry location, away from moisture and dust.
11
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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.
Aerobic Exercise
To strengthen your cardiovascular system, your exer-
cise 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.
WARNING:
Before beginning this
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.
HOW TO MEASURE YOUR HEART RATE
EXERCISE INTENSITY
To measure your
heart rate, first exer-
cise for at least four
minutes. Then, stop
exercising and place
two fingers on your
wrist as shown.
Take a six-second
heartbeat count,
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.
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 parts:
A warm-up, consisting of 5 to 10 minutes of stretching
and light exercise (see page 13). A proper warm-up
increases your body temperature, heart rate, and cir-
culation in preparation for 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.
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.)
Burning Fat
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.
To burn fat effectively, you must exercise at a low
intensity level for a sustained period of time. During
the first few minutes of exercise, your body uses easi-
ly accessible carbohydrate calories for energy. 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 burn-
ing, adjust the intensity of your exercise until your
heart rate is near the middle number.
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.
Remember, the key to success is make exercise a
regular and enjoyable part of your everyday life.
12
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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.
5
5. Inner Thigh Stretch
Sit with the soles of your feet together and your knees outward.
Pull your feet toward your groin area as far as possible. Hold for
15 counts, then relax. Repeat 3 times. Stretches: Quadriceps
and hip muscles.
13
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—
PART LIST Model No. 831.285960
R0501A
Key
Key
No. Qty.
Description
No. Qty.
Description
1
2
3
4
5
6
7
8
1
2
1
1
1
1
2
1
2
1
4
2
15
1
1
6
2
2
2
2
1
2
1
1
1
1
4
1
4
1
1
1
2
1
2
2
Frame
T-Handle Endcap
Upright
Right Side Shield
Left Side Shield
Console
Foam Handlebar Grip
Left Handlebar
M8 Lock Washer
T-Handle
Rear Pedal Arm Bushing
Pedal Arm
M5 x 16mm Screw
Resistance Strap
Strap Buckle
M4 x 19mm Round Head Screw
1/4” Nylon Locknut
Adjustment Bracket
M6 Eyebolt
M10 Nylon Jam Nut
Flywheel Axle
Flywheel Bearing
Flywheel
Magnet
Sensor Wire/Reed Switch
Resistance Control/Cable
Stabilizer Endcap
Tension Spring
M10 Nylon Locknut
Belt
Left Pedal
Pulley w/Shaft
Crank Arm Extension
M4 x 16mm Screw
5/16” Zinc Bolt
Pulley Bearing
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
66
#
2
17
2
1
2*
4
4*
1
1
4
1
1
2
1
4
1
2
2
2
4*
2*
1
2
1
2
1
1
1
1
2
1
2
1
1
1
Pedal Disk
M4 x 16mm Round Head Screw
Handlebar Spacer
Side Shield Bracket
Pedal Arm Spacer
Pedal Arm Bushing
3/4” Axle Cap
M4 x 16mm Flat Head Screw
Right Pedal
#8 Flat Washer
Clamp Nut
Clamp Bolt
Weld Spacer
Resistance Knob
M4 x 25mm Screw
Return Spring
9
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
36
M10 Washer
M6 x 16mm Screw
M6 Black Nylon Locknut
Pivot Bushing
5/8” Axle Cap
M4 x 64mm Screw
Crank Arm
3/4” Plastic Spacer
5/16” Zinc Washer
Right Handlebar
Extension Wire
Lower Cable
Console Back
Battery Cover
User’s Manual
Side Shield Decal
Warning Decal
#
#
#
#
Hardware Kit
Grease Packet
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
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—
EXPLODED DRAWING Model No. 831.285960
R0501A
13
58
4
50
6
13
38
66
62
65
13
38
51
38
57
63
26
56
56
5
38
38
38
38
49
30
45
43
42
7
3
8
54
55
49
56
29
12
16
17
42
43
56
39
2
2
57
10
41
20
18
11
27
19
22
22
23
31
53
17
18
53
39
24
47
42
28
1
13
19
21
20
48
9
46
52
35
43
61
59
12
64
34
36
60
41
33
40
13
36
11
13
27
25
32
16
37
33
11
44
43
15
27
14
59
61
9
35
27
37
13
15
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The model number and serial number of your PROFORM® 545E
are listed on a decal attached to the frame. See the front cover of
this manual to find the location of the decal.
Model No. 831.285960
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.
QUESTIONS?
If you find that:
• you need help assembling or
operating the PROFORM® 545E
When requesting help or service, or ordering parts, please be pre-
pared to provide the following information:
• a part is missing
• The NAME OF THE PRODUCT (PROFORM® 545E)
• The MODEL NUMBER OF THE PRODUCT (831.285960)
• The KEY NUMBER OF THE PART (see page 14)
• The DESCRIPTION OF THE PART (see page 14).
• 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
Part No. 175096 R0501A
Printed in China © 2001 ICON Health & Fitness, Inc.
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