Life Fitness 5500HR User manual
Model 5500HR Treadmill
Customer Support Services
SERVICE MANUAL
©1996 Life Fitness. All rights reserved. The Life Fitness trademark is register in the U.S. Patent and 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
Life Fitness Model 5500HR Treadmill
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL
In the unlikely event that an operating problem may occur with your Life Fitness model 5500HR aerobic trainer,
this Service Manual will instruct and guide you on the quickest, most efficient manner in which to approach the
situation. This Service Manual has been separated into a total of Five Sections for quick reference:
q INTRODUCTION
q TABLE OF CONTENTS
Section I
q TROUBLESHOOTING GUIDES
Section II
q DIAGNOSTIC TESTS
Section III
q MODEL 5500HR "How To..." GUIDES
Section IV
q PARTS IDENTIFICATION
Section V
q WIRING DIAGRAMS
q PREVENTIVE MAINTENANCE
q COMMUNICATING BY FAX
If an operating problem should arise, turn to the TROUBLESHOOTING GUIDES and attempt to isolate what is
causing the malfunction. The GUIDES are listed by symptoms and follow with suggestions as to the most probable
cause of the problem.
Once you have pin pointed the source of the problem, turn to the appropriate "How To..." section and review the
proper procedures for removing, replacing or adjusting a part. The "How To..." sections are 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 through Friday from 8:00 AM to 6:00 PM
(C.S.T.). When you place a call, in order to speed our response to your particular situation, please have the
following information available for the customer support phone technician who will be prepared to assist you:
1. The Treadmill model type (5500HR)
2. The six digit serial number ( Located next to the ON/OFF switch )
Serial Number:
3. The symptom of the problem you are experiencing
4. The part name and number you need to order
When you receive your order, review the appropriate "How To..." section and follow the step by step procedures
designed to help you install the part quickly and correctly.
If you have any questions or comments please phone, mail, or fax us at one of the numbers listed below.
CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue, Franklin Park, IL 60131
Phone (800) 351-3737 Toll Free or (847) 451-0036 FAX (800) 216-8893 Toll Free or (847) 288-3702
Life Fitness Model 5500HR Treadmill
TABLE OF CONTENTS
Introduction (How To Use This Service Manual)
Table of Contents
SECTION I Page
Troubleshooting Guides
Belt Slips Or Display Reads Error..............................................................................................1
Noisy Treadmill...........................................................................................................................2
Display Does Not Illuminate Or Respond To Input....................................................................3
Unit Resets Randomly................................................................................................................4
No Power.....................................................................................................................................5
Striding Belt Comes In Contact With Frame And End Caps......................................................6
Display Reads Errors..................................................................................................................7
Lift Error......................................................................................................................................8
Heart Rate System ......................................................................................................................9
SECTION II
Diagnostic Tests.......................................................................................................................................1-4
SECTION III
How To...REMOVE AND REPLACE THE
How To...ADJUST AND TENSION THE STRIDING BELT .......................................................................... 12,13
SECTION IV
Parts Identification ................................................................................................................................... 1-3
SECTION V
Wiring Block Diagram............................................................................................................................... 1
Preventive Maintenance Tips................................................................................................................... 2
Communicating By Fax............................................................................................................................3,4
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
Display Console..........................................................................................................................14
Telemetry Receiver .....................................................................................................................15
Lift Actuator ................................................................................................................................ 16
On/Off Switch..............................................................................................................................17
Choke...........................................................................................................................................18
Transformer.................................................................................................................................19
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: "Slowdown". Belt slips during footfall or desired speed is reduced.
Malfunction Probable Cause Corrective Action
Belt slips during footfall
Desired speed is reduced
Insufficient power source.
Belt slips on front roller during
stall test.
Drive belt slips on sheave.
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 Diagnostics Section)
q Replace deck and belt.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
1
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Noisy Treadmill
Malfunction Probable Cause Corrective Action
Knocking sound at rear of
machine
Knocking sound coming
from deck
Rubbing sound from
underneath machine
Squeaking noise
Squeaking noise at higher
speeds
Loud "groaning" sound
heard from front of
machine while elevating
Loud "groaning" on
footfall
Wax build-up on roller
Faulty rear roller bearings.
Loose deck screws.
Foreign objects may be stuck
underneath the machine.
Lifesprings may be misaligned.
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 Lifesprings.
q Replace Drive Motor Belt.
q Replace Drive Motor.
q Spray with gear/belt lubricant.
q Align pulleys if necessary.
q Replace Drive Motor.
q Replace Lift Motor.
q Replace Drive Motor.
q Perform "Power Mode” test.
(See Diagnostics Section)
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
2
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Display Does Not Illuminate or Respond To Input
Malfunction Probable Cause Corrective Action
Display does not illuminate
when machine is powered
on.
Insufficient power source.
Pinched wire connection
Loose connection at Display
Console or Heatsink Control
Board.
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 connections.
q Replace Heatsink Control Board.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
3
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Unit Resets Randomly
Malfunction Probable Cause Corrective Action
Unit resets randomly
Insufficient power source.
Damaged line cord.
Line cord improperly seated in
socket.
Pinched display harness.
Loose connections at heatsink
control board and display.
Safety key not making proper
contact.
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 display.
q Place safety key in proper position.
q Replace switch.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
4
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Symptom: No Power
No Power
I/O or On/Off switch.
Insufficient power source.
Safety key at I/O switch
Damaged line cord.
Line cord improperly seated in
socket.
Pinched cable in Control Panel
Power module.
• On/Off switch
• Heatsink
q Is unit turned on?
q Plug treadmill into a dedicated 120V, 15
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
Faulty Display Console.
Life Fitness Model 5500HR Treadmill
q OHM ON/OFF switch for continuity.
q Using a meter, check for voltage at TP1
for 5v DC and TP2 for 8v DC with
respect to ground.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
5
TROUBLESHOOTING GUIDE
Symptom: Belt Comes In Contact With Frame and Rear End Cap Panel
Malfunction Probable Cause Corrective Action
The belt is traveling beyond
the tracking guides.
Striding belt mis-alignment
by more than 1/4”.
Worn striding belt
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 Support Services
1-847-451-0036 or 1-800-351-3737
6
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Symptom: Display reads Errors
Belt Moving Error
No ZX
Belt Over Speed
No Blanking
Loose connections at electrical
outlet.
User has overdriven belt.
Loose cable connection.
Opto Sensor not in the proper
position.
Dust or other obstrustion
blocking opto sensor from
reading.
Faulty opto sensor.
User has overdriven belt.
Display has been taken out of
its screen saver mode.
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
screensaver mode.
Stop, Stop, Stop
Safety Key not making proper
contact
Faulty Safety Key Switch
q Verify Safety Key is in proper position
q Replace Safety Key Switch in Control
Panel
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
7
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Lift Error
Malfunction Probable Cause Corrective Action
Unit will not incline
Line cord in postioned over the
lift leg assembly
Faulty Home Switch.
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 1-800-351-3737
8
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Heart Rate System Does Not Respond, Erratic Heart Rate Reading
Symptom Probable Cause Corrective Action
No heart rate or display
reads (No chest strap
detected) Erratic Heart
Rate
HR receiver not installed.
No HR transmitter (Chest
strap).
Electrodes on transmitter are
dry.
No HR reading.
HR receiver may be near an
electrical device that could
interfere 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 connector to display console.
q Replace HR harness cable.
q Replace HR receiver and/or transmitter.
q Replace display console.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
9
Life Fitness Model 5500HR Treadmill
NOTES:
10
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)
1
Loading...