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:

qINTRODUCTION

qTABLE OF CONTENTS

Section I

qTROUBLESHOOTING GUIDES

Section II

qDIAGNOSTIC TESTS

Section III

qMODEL 5500HR "How To..." GUIDES

Section IV

qPARTS IDENTIFICATION

Section V

qWIRING DIAGRAMS

qPREVENTIVE MAINTENANCE

qCOMMUNICATING 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 [phone] Toll Free or [phone] FAX [phone] Toll Free or [phone]

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
	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
	On/Off Switch ..............................................................................................................................	17
	Choke...........................................................................................................................................	18
	Transformer.................................................................................................................................	19
SECTION IV
Parts Identification ...................................................................................................................................		1-3
SECTION V

Wiring Block Diagram...............................................................................................................................	1
Preventive Maintenance Tips ...................................................................................................................	2
Communicating By Fax ............................................................................................................................	3,4

Life Fitness Model 5500HR Treadmill

TROUBLESHOOTING GUIDE

Symptom: "Slowdown". Belt slips during footfall or desired speed is reduced.

Malfunction

Belt slips during footfall

Desired speed is reduced

Probable Cause

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).

Corrective Action

qPlug treadmill into a dedicated 120V, 15 amp circuit. (See Operations Manual)

qCheck belt & re-tension as necessary.

qCheck belt & re-tension as necessary.

qInspect belt and deck for excessive wear. Replace any defective part.

qPerform "Power Mode” test. (See Diagnostics Section)

qReplace deck and belt.

For Assistance Call:

Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737

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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	q	Run unit for 10 hours of ontime use to
		distribute wax evenly
Faulty rear roller bearings.	q	Replace rear roller assembly.
Loose deck screws.	q	Tighten deck screws.
Foreign objects may be stuck	q	Inspect underneath belt and machine.
underneath the machine.		Remove any debris or accumulation on
		debris brush.
Lifesprings may be misaligned.	q	Reposition Lifesprings.
Drive Motor Belt may be worn	q	Replace Drive Motor Belt.
or damaged.
Noisy Drive Motor.	q	Replace Drive Motor.
Drive Motor Belt may be	q	Spray with gear/belt lubricant.
squeaking.
Noisy Drive Motor.	q	Align pulleys if necessary.
	q	Replace Drive Motor.
Faulty Lift Motor.	q	Replace Lift Motor.

Faulty Drive Motor.	q	Replace Drive Motor.
High deck and belt friction.	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	Insufficient power source.	q Plug treadmill into a dedicated 120V, 15
when machine is powered		amp circuit
on.		q Turn power ON at switch while pressing
		the Speed Down Ñ Key and perform
		Display test.
	Pinched wire connection	q Check all electrical connections.
		q Check cable in Control Panel for pinched
		cable
	Loose connection at Display	q Secure connections at Display Console
	Console or Heatsink Control	and Heatsink Control Board.
	Board.
	Faulty Display Console.	q Replace Display Console.
	Faulty Heatsink Control Board.	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.	q	Plug treadmill into a dedicated 120V,
			15 amp circuit.
	Damaged line cord.	q	Replace line cord.
	Line cord improperly seated in	q	Inspect power connection at electrical
	socket.		outlet and at machine for proper contact.
	Pinched display harness.	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.
	Loose connections at heatsink	q	Secure connections at heatsink control
	control board and display.		board and display.
	Safety key not making proper	q	Place safety key in proper position.
	contact.
	Faulty safety key switch	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

				Symptom: No Power
Malfunction		Probable Cause		Corrective Action
No Power	I/O or On/Off switch.		q	Is unit turned on?
	Insufficient power source.		q	Plug treadmill into a dedicated 120V, 15
				amp circuit.
			q Using a meter, verify power at outlet.
	Safety key at I/O switch		q	Safety key broken or missing. Replace
				safety key.
	Damaged line cord.		q	Replace line cord.
	Line cord improperly seated in		q	Inspect power connection at electrical
	socket.			outlet and at machine for proper contact.
	Pinched cable in Control Panel		q	Verify cable from Display to handrail
				cable is not crimped between (tray)
				Control Panel and the handrail.
			q	Replaced damaged cable.
	Power module.		q	Replace faulty parts
	∙	On/Off switch
	∙	Heatsink
	Faulty Display Console.		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

Life Fitness Model 5500HR Treadmill

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	q Replace worn belt.
Striding belt needs to be	q Refer to belt tensioning procedure in
re-tensioned.	operation or service manual.
User pushes belt.	q Center belt according to belt centering
	technique described in operation
	manual.
Unit is not level.	q Level treadmill by adjusting leveling
	legs.
Belt Skewed	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

Symptom: Display reads Errors

Malfunction

Belt Moving Error

No ZX

Belt Over Speed

No Blanking

Stop, Stop, Stop

Probable Cause		Corrective Action
Loose connections at electrical	q Verify the plug is seated properly in the
outlet.		electrical outlet.
User has overdriven belt.	q	Reset the unit.
Loose cable connection.	q Check cable connection at Console
		and CPU board.
Opto Sensor not in the proper	q	Adjust opto sensor.
position.
Dust or other obstrustion	q	Clean opto sensor.
blocking opto sensor from
reading.
Faulty opto sensor.	q Replace faulty opto sensor.
User has overdriven belt.	q	Reset the unit.
Display has been taken out of	q Power unit off and on to reset
its screen saver mode.		screensaver mode.
Safety Key not making proper	q Verify Safety Key is in proper position
contact
Faulty Safety Key Switch	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

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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	q Position the line cord to its proper
	lift leg assembly	position.
		q Perform incline test (See Diagnostics).
	Faulty Home Switch.	q Preform incline test (See Diagnostics).
		If unit elevates , check home switch
		with an ohm meter. Replace faulty
		Home Switch.
	Faulty Lift Actuator.	q Replace Lift Actuator.
	Unit will not elevate to 15%	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

No heart rate or display reads (No chest strap detected) Erratic Heart Rate

Probable Cause	Corrective Action

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.

qInstall HR receiver into HR receiver jack on underside of handlebar tray.

qInstall transmitter (chest strap).

qWet electrodes on transmitter.

qEnter into DIAGNOSTICS test to verify a good heart rate (See Section II).

qMove treadmill to another location.

qPlug HR connector to display console.

qReplace HR harness cable.

qReplace HR receiver and/or transmitter.

qReplace display console.

For Assistance Call:

Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737

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Life Fitness Model 5500HR Treadmill

NOTES:

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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