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1

Life Fitness Model 5500HR Treadmill

DIAGNOSTIC TESTS

PURPOSE:

This Section describes the test procedures for the Life Fitness 5500HR Treadmill Display Console Board including
those for the Heart Rate feature.

SCOPE:

Diagnostic procedures will test the Display Console Board as used in the final Treadmill assembly. These
procedures will insure proper functioning of the Console LED’s, Keys and Displays as well as identify the Console
version.

PROCEDURE:

Begin with the Treadmill ON/OFF switch turned to OFF. To enter diagnostic mode, you must power unit 

ON

 while

pressing the designated key for each mode of the diagnostics.

(Continued)

Summary of Contents for Lifecycle 5500HR

Page 1: ...Model 5500HR Treadmill Customer Support Services SERVICE MANUAL ...

Page 2: ... Trademark Office Certificate No 1 400 502 issued July 8 1986 FlexDeck Zone Trainer and Heart Rate Zone Training are trademarks of Life Fitness Any use of these trademarks without the express written consent of Life Fitness is forbidden U S Patent Numbers 3 767 195 and 4 358 105 M051 00K36 A032 12 96 ...

Page 3: ... organized by replaceable part or assembly name and each page lists the Tools Required to complete that specific function Refer to Section IV to identify the proper name and number of the part you will now need to order to repair your machine A form to order by FAX has also been included in Section V for your convenience To order a part call Life Fitness Customer Support Services any Monday throug...

Page 4: ...rrors 7 Lift Error 8 Heart Rate System 9 SECTION II Diagnostic Tests 1 4 SECTION III How To REMOVE AND REPLACE THE Motor Cover 1 Heatsink Control Board 2 3 Drive Motor Belt 4 5 Drive Motor Assembly 6 Rear End Cap Panel 7 Front Roller Assembly 8 Rear Roller Assembly 9 Deck 10 Striding Belt 11 How To ADJUST AND TENSION THE STRIDING BELT 12 13 Display Console 14 Telemetry Receiver 15 Lift Actuator 16...

Page 5: ...e User is pushing striding belt Belt Deck Malfunction Deck laminate is worn through Underside of striding belt is worn or glazed hard glossy q Plug treadmill into a dedicated 120V 15 amp circuit See Operations Manual q Check belt re tension as necessary q Check belt re tension as necessary q Inspect belt and deck for excessive wear Replace any defective part q Perform Power Mode test See Diagnosti...

Page 6: ...d Drive Motor Belt may be worn or damaged Noisy Drive Motor Drive Motor Belt may be squeaking Noisy Drive Motor Faulty Lift Motor Faulty Drive Motor High deck and belt friction q Run unit for 10 hours of ontime use to distribute wax evenly q Replace rear roller assembly q Tighten deck screws q Inspect underneath belt and machine Remove any debris or accumulation on debris brush q Reposition Lifesp...

Page 7: ... Faulty Display Console Faulty Heatsink Control Board q Plug treadmill into a dedicated 120V 15 amp circuit q Turn power ON at switch while pressing the Speed Down Key and perform Display test q Check all electrical connections q Check cable in Control Panel for pinched cable q Secure connections at Display Console and Heatsink Control Board q Replace Display Console q Check all electrical connect...

Page 8: ...act Faulty safety key switch q Plug treadmill into a dedicated 120V 15 amp circuit q Replace line cord q Inspect power connection at electrical outlet and at machine for proper contact q Check all display connections q Verify cable from Display to handrail cable is not crimped between tray Control Panel and the handrail q Replaced damaged cable q Secure connections at heatsink control board and di...

Page 9: ... amp circuit q Using a meter verify power at outlet q Safety key broken or missing Replace safety key q Replace line cord q Inspect power connection at electrical outlet and at machine for proper contact q Verify cable from Display to handrail cable is not crimped between tray Control Panel and the handrail q Replaced damaged cable q Replace faulty parts q OHM ON OFF switch for continuity q Using ...

Page 10: ...elt Striding belt needs to be re tensioned User pushes belt Unit is not level Belt Skewed q Replace worn belt q Refer to belt tensioning procedure in operation or service manual q Center belt according to belt centering technique described in operation manual q Level treadmill by adjusting leveling legs q Replace front roller bolt with Belt skew kit For Assistance Call Life Fitness Customer Suppor...

Page 11: ...opto sensor User has overdriven belt Display has been taken out of its screen saver mode Safety Key not making proper contact Faulty Safety Key Switch q Verify the plug is seated properly in the electrical outlet q Reset the unit q Check cable connection at Console and CPU board q Adjust opto sensor q Clean opto sensor q Replace faulty opto sensor q Reset the unit q Power unit off and on to reset ...

Page 12: ...witch Faulty Lift Actuator Unit will not elevate to 15 q Position the line cord to its proper position q Perform incline test See Diagnostics q Preform incline test See Diagnostics If unit elevates check home switch with an ohm meter Replace faulty Home Switch q Replace Lift Actuator q Check calibration of Lift Motor For Assistance Call Life Fitness Customer Support Services 1 847 451 0036 or 1 80...

Page 13: ...rfere with the HR i e television HR connector not plugged in Check for pinched wire Bad HR receiver or transmitter Bad display console q Install HR receiver into HR receiver jack on underside of handlebar tray q Install transmitter chest strap q Wet electrodes on transmitter q Enter into DIAGNOSTICS test to verify a good heart rate See Section II q Move treadmill to another location q Plug HR conn...

Page 14: ...10 Life Fitness Model 5500HR Treadmill NOTES ...

Page 15: ...E Diagnostic procedures will test the Display Console Board as used in the final Treadmill assembly These procedures will insure proper functioning of the Console LED s Keys and Displays as well as identify the Console version PROCEDURE Begin with the Treadmill ON OFF switch turned to OFF To enter diagnostic mode you must power unit ON while pressing the designated key for each mode of the diagnos...

Page 16: ... KEY 1st Press Distance LED Lit Miles 2nd Press Time LED Lit Motor ON Time hours 3rd Press Incline LED Lit Lift Motor run time 4th Press Cal Hr LED Lit Lift Motor percentage of elevation usage 5th Press Speed LED Lit Current limiter Activation Press ENTER a fourth time and this will give you the Software Version on the treadmill For example the Display will read 2 7EE1 2 7 Software Version E Engli...

Page 17: ...0V When the LED is ON the unit is 220V The sixth LED from the top indicates the elevation Home Switch When the LED is OFF the Home Switch is engaged and the unit is at Zero elevation When the LED is ON the Home Switch is disengaged and the unit is at a non zero elevation The Bottom LED is the Emergency Stop Switch condition When the LED is ON the Emergency Stop Switch is engaged and the unit will ...

Page 18: ...ed mode HEART RATE MODE The user must have the Heart Rate Transmitter and Receiver attached in their proper positions for the Heart Rate to display By pressing ENTER the users Heart Rate will appear on the display s readout POWER MODE Start with the Treadmill turned OFF at the ON OFF switch NOTE DO NOT STAND ON THE STRIDING BELT DURING POWER UP Power up the unit while holding the INCLINE UP KEY Th...

Page 19: ...s screwdriver Step 1 Turn the power OFF at the ON OFF switch and then unplug the unit from the electrical outlet Step 2 Using a Phillips screwdriver remove the four SCREWS securing the MOTOR COVER and remove the damaged MOTOR COVER Step 3 Place the new MOTOR COVER in position and replace the four SCREWS ...

Page 20: ...T TO NOTE THE LOCATIONS OF THE CONNECTORS PRIOR TO UNPLUGGING THEM FROM THE HEATSINK CONTROL BOARD Step 4 Unplug the eight CONNECTORS from the HEATSINK CONTROL BOARD Step 5 Remove the red CAPACITOR CAP NOTE THE POLARITY OF THE WIRES ON THE CAPACITOR POSITIVE RED NEGATIVE BLACK Step 6 Using a Phillips screwdriver remove the two SCREWS securing the wires to the top of the CAPACITOR from the HEATSINK...

Page 21: ...3 Life Fitness Model 5500HR Treadmill HOW TO REMOVE AND REPLACE THE HEATSINK CONTROL BOARD Continued CPU CONNECTION ...

Page 22: ...ur NUTS and WASHERS securing the DRIVE MOTOR ASSEMBLY to the MOTOR PAN Step 6 With a socket wrench 7 16 loosen and remove the TENSIONING BOLT from the DRIVE MOTOR ASSEMBLY MOUNTING BRACKET Step 7 Push the DRIVE MOTOR ASSEMBLY towards the FRONT ROLLER to relieve the tension on the DRIVE MOTOR BELT Roll the DRIVE MOTOR BELT off the DRIVE MOTOR PULLEY ASSEMBLY HELPFUL HINT MARK THE POSITION OF THE RE...

Page 23: ...o their proper positions The DRIVE MOTOR BELT tension should be set at 100 ft lbs If belt guages are not available set the DRIVE MOTOR BELT tension to 1 4 deflection Step 14 Refer to How To ADJUST AND TENSION THE STRIDING BELT for proper belt tensioning instructions NOTE DRIVE BELT TENSION SHOULD BE BETWEEN 90 EXISTING AND 100 NEW FT LBS STRIDING BELT TENSION SHOULD BE 65 IF GUAGE IS AVAILABLE A P...

Page 24: ... HELPFUL HINT MARK OR SCORE THE PLACEMENT OF THE DRIVE MOTOR MOUNTING BRACKET THIS WILL HELP WHEN RE TENSIONING THE DRIVE MOTOR BELT Step 6 With a socket wrench 1 2 loosen the four NUTS and WASHERS securing the DRIVE MOTOR ASSEMBLY to the MOTOR PAN Step 7 With a socket wrench 7 16 loosen and remove the TENSIONING BOLT from the DRIVE MOTOR ASSEMBLY MOUNTING BRACKET NOTE TAKE A MOMENT TO NOTE THE LO...

Page 25: ...1 Turn the power OFF at the ON OFF switch and then unplug the unit from the electrical outlet Step 2 Using a Phillips screwdriver remove the three SCREWS from each side of the REAR END CAP PANEL and remove the damaged REAR END CAP PANEL Step 3 Position the new REAR END CAP PANEL in place and replace the three SCREWS to each side ...

Page 26: ...wrench 1 4 alternately loosen the REAR TENSIONING BOLTS an equal number of turns counter clockwise to slacken the STRIDING BELT Step 8 Using an open end wrench 1 2 loosen the screw on the left side of the FRONT ROLLER Step 9 Carefully lift the left side of the FRONT ROLLER ASSEMBLY from the FRAME BRACKET Note the location of the star washer with respect to the FRAME BRACKET Step 10 Carefully pull ...

Page 27: ...securing each side of the REAR ROLLER MOUNTING BRACKETS Alternate between each of the TENSIONING BOLTS rotating each BOLT two 2 full turns at a time Step 4 Remove the worn REAR ROLLER from the machine Step 5 Position the new REAR ROLLER against the MOUNTING BRACKETS and reverse steps 1 through 3 to return all parts to their proper locations Step 6 Refer to How To ADJUST AND TENSION THE STRIDING BE...

Page 28: ...TS an equal number of turns counter clockwise to slacken STRIDING BELT Alternate between each of the TENSIONING BOLTS rotating each BOLT a maximum of two 2 full turns Step 6 Using a hex key wrench 5 32 remove the four corner DECK SCREWS and carefully slide DECK from under the STRIDING BELT Step 6 Using a Phillips screwdriver loosen and remove the four screws securing the two BELT GUIDE BRACKETS lo...

Page 29: ...ve the MOTOR COVER See How To Step 3 Remove the REAR ROLLER See How To Step 4 Remove the DECK See How To Step 5 Using an open end wrench 1 2 loosen the user left side of the FRONT ROLLER ASSEMBLY Step 6 Carefully lift the user left side of the FRONT ROLLER ASSEMBLY and slide the STRIDING BELT from the FRONT ROLLER Step7 Reposition the new STRIDING BELT around the FRONT ROLLER ASSEMBLY Reverse step...

Page 30: ...exceeding one full turn See Tracking Centering an Existing or New Striding Belt on previous page Repeat Step 3 Adjusting Setting Proper Tension for a New Striding Belt Step 1 After installation but before tensioning place two pieces of tape exactly 38 1 2 38 5 inches apart on both right and left edges of the striding belt Step 2 Alternately tighten the right and left tensioning bolts 1 4 turn cloc...

Page 31: ...AL BELT TENSION AT THE PIVOT POINT CAUTION DO NOT OVER TIGHTEN THE TENSIONING BOLTS WHILE MAKING BELT ADJUSTMENTS OVER TIGHTENING OF BOLTS MAY OVER STRETCH AND DAMAGE THE STRIDING BELT AS WELL AS PLACE AN UNNECESSARY LOAD ON THE REAR ROLLER BEARINGS Step 3 Repeat adjustments until the STRIDING BELT appears centered Allow the machine to continue running for several minutes to observe if the trackin...

Page 32: ...e top of the CONTROL PANEL from the corresponding CONNECTOR in the back of the DISPLAY CONSOLE Disconnect the 4 PIN CONNECTOR of the HEART RATE wire harness into the corresponding CONNECTOR in the back of the DISPLAY CONSOLE Step 4 Replace the DISPLAY CONSOLE by reversing Steps 1 and 2 When installing the four SCREWS to secure the DISPLAY CONSOLE to the CONTROL PANEL tighten the SCREWS in a criss ...

Page 33: ...e the four tabs from the CONTROL PANEL Step 3 Unplug and remove the FOAM encased TELEMETRY HEART RATE RECEIVER from the TELEMETRY HEART RATE COVER Step 4 Carefully remove the TELEMETRY HEART RATE RECEIVER from its protective FOAM sleeve Step 5 Unplug the TELEMETRY HEART RATE RECEIVER from the WIRE HARNESS receptacle and remove the faulty TELEMETRY HEART RATE RECEIVER Step 6 Install the new TELEMET...

Page 34: ...emove the COTTER PIN from the CLEVIS PIN located under the LIFT CHANNEL and then remove the CLEVIS PIN securing the LIFT ACTUATOR to the LIFT CHANNEL Step 7 Remove each of the two RETAINING CLIPS securing the PIVOT PINS to the LIFT ACTUATOR through the LIFT FRAME Remove the worn LIFT ACTUATOR Step 8 Place the new LIFT ACTUATOR into position and replace the CLEVIS and COTTER pins to attach the new ...

Page 35: ...ONS OF THE CONNECTORS PRIOR TO UNPLUGGING THEM FROM THE SWITCH Step 3 Remove the two CONNECTORS from the SWITCH Step 4 Remove the two SCREWS securing the SWITCH to the MOTOR PAN and remove the faulty SWITCH Step 5 Place the new SWITCH in position and reverse steps 1 through 4 to return all parts to their proper locations Step 6 Some models are equipped with a SAFETY STOP SWITCH If you are installi...

Page 36: ...he STRIDING BELT completes at least one revolution around the rollers this will aid in releasing any electrical charge which may be held in the CAPACITOR Remove the CAPACITOR CAP and use a DC Voltmeter to check and insure that the CAPACITOR does not hold a charge prior to proceeding to Step 4 Step 4 Using a socket and wrench loosen and remove the four NUTS securing the CHOKE to the STUDS on the MO...

Page 37: ...urn the power OFF at the ON OFF switch and then unplug the unit from the electrical outlet Step 2 Remove the MOTOR COVER See How To Step 3 Using a Phillips screwdriver loosen and remove the two SCREWS securing the TRANSFORMER to the MOTOR PAN Step 4 Lift out the faulty TRANSFORMER and unplug the CONNECTOR from the HEATSINK CONTROL BOARD Step 5 Place the new TRANSFORMER into position and reverse St...

Page 38: ...20 Life Fitness Model 5500HR Treadmill NOTES ...

Page 39: ...6 00002 0007 Handle Assy LT GK36 00002 0008 19 Belt Drive Motor OK36 01011 0002 20 Actuator Lift OK36 01012 0004 21 Pin Lift OK40 01061 0000 22 Panel Front OK36 01013 0001 23 Guides Belt OK36 01061 0000 24 Pulley Sheave OK36 01058 0001 Cable Assembly NOT Shown 25 Striding Belt OK45 01005 0001 Cons H R AK36 00010 0001 26 Deck OK36 01124 0000 Safety Switch AK36 00029 0000 27 Tecspak LF Spring OK40 0...

Page 40: ...2 Life Fitness Model 5500HR Treadmill PARTS DESCRIPTION ...

Page 41: ...3 Life Fitness Model 5500HR Treadmill PARTS DESCRIPTION ...

Page 42: ...4 Life Fitness Model 5500HR Treadmill NOTES ...

Page 43: ...1 Life Fitness Model 5500HR Treadmills WIRING BLOCK DIAGRAM ...

Page 44: ...SPECT REPLACE Console Mounting Bolts INSPECT Frame CLEAN INSPECT Striding Belt Top CLEAN VACUUM INSPECT Deck INSPECT Power Cord INSPECT Display Console CLEAN INSPECT Handlebar CLEAN INSPECT Handrail and Handlebar Bolts INSPECT Front Roller INSPECT Rear Roller INSPECT Stop Key INSPECT Rear Roller Guard CLEAN INSPECT Poly V Belt INSPECT ...

Page 45: ...blem we have included for your convenience a FAX form on the following page Simply make a copy or copies of the FAX sheet and fill in the necessary information You may FAX us at any time 24 hours a day to either of the numbers shown A Life Fitness service representative will process your order or respond to your problem as quickly as possible ...

Page 46: ...TACT NAME METHOD OF SHIPMENT 1 DAY 2 DAY GROUND PARTS ORDER FORM ITEM NO PART NUMBER DESCRIPTION QUANTITY 1 2 3 4 5 6 PRODUCT TROUBLESHOOTING PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM TIME RECEIVED TIME COMPLETED TECHNICIAN NAME Life Fitness Model 5500HR Treadmills NOTES ...

Page 47: ...6 Life Fitness Model 5500HR Treadmills NOTES ...

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