Life Fitness Lifecycle 3500 Series User manual

Lifecycle 3500, 4500, 5500 Series
Exercise Bikes
Customer Support Services
SERVICE MANUAL

Lifecycle 3500, 4500, 5500 Series Exercise Bikes
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL
In the unlikely event that an operating problem may occur with your Lifecycle Exercise Bikes, this Service Manual
will inform and instruct you or your maintenance engineer on how to repair your machine in the quickest, most
efficient manner.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
qDIAGNOSTICS TESTS
Section III
q”How To... “ GUIDES
Section IV
qPARTS IDENTIFICATION
Section V
qMODEL IDENTIFICATION AND SERIAL NUMBER LOCATION
qPREVENTIVE MAINTENANCE TIPS
qWIRING BLOCK DIAGRAMS
qORDERING 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 pinpointed 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.
If you do not have a part in stock, a form to order by FAX has been included in Section V for your convenience or
you can 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 service phone technician who will be prepared to assist you:
1. The equipment model type ( i.e. 5500 )
2. The serial number (Located on the underside of the front stabilizer bar)
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]

©1997 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. Lifecycle, Lifepulse, 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.
M051-00K17-A079
6-97

Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TABLE OF CONTENTS
INTRODUCTION (How to use this Service Manual)
TABLE OF CONTENTS
SECTION I
TROUBLESHOOTING GUIDES PAGE
No Power........................................................................................................................ 1
Display Console Initializes, But Does Not Stay On...................................................... 2
Lights Flicker Or Fade In And Out/Erratic Display....................................................... 3
Flashing Prompt Remains On....................................................................................... 4
Loads At Start Of A Program......................................................................................... 5
Loads In Middle Of A Program...................................................................................... 6
Keys Do Not Respond (Start Button Not Included)...................................................... 7
Exercise Bike Is Making A Loud Noise......................................................................... 8
Level Changes During Program.................................................................................... 9
Difficult To Pedal: Display Is Off................................................................................... 10
Too Easy To Pedal......................................................................................................... 11
Tension Stays The Same............................................................................................... 12
Will Not Pedal Forward.................................................................................................. 13
Flashing Prompt Goes Off When Start Button Is Released......................................... 14
SECTION II
DIAGNOSTICS
Lifecycle 3500, 4500, 5500 Series Exercise Bikes ........................................................ 1-3
SECTION III
How To...REMOVE AND REPLACE THE
Alternator........................................................................................................................ 1
Alternator Control Board............................................................................................... 2
Alternator Belt................................................................................................................ 3
Battery ............................................................................................................................ 4
Chain............................................................................................................................... 5
Crank Bearing / Nut Assemblies ................................................................................... 6,7
Footstraps...................................................................................................................... 8
Handlebar Assembly/Display Console.......................................................................... 9,10
Free-Wheel Assembly.................................................................................................... 11
Housing.......................................................................................................................... 12
Pedals............................................................................................................................. 13
Seat/Seat Post................................................................................................................ 14
Adjustable Foot Cap ...................................................................................................... 15
SECTION IV
PARTS IDENTIFICATION
Lifecycle 3500, 4500, 5500 Series Exercise Bikes ........................................................ 1,2
SECTION V
MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION................................................. 1
PREVENTIVE MAINTENANCE TIPS........................................................................................... 2,3
WIRING BLOCK DIAGRAMS....................................................................................................... 4
COMMUNICATING BY FAX......................................................................................................... 5,6

1
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: NO POWER
Symptom Probable Cause Corrective Action
Display Console does not
light up Not pedaling fast enough
Low battery voltage
Loose wire connections or
defective wire harness
Defective Display Console
Defective Alternator Control
Board
Defective Alternator
qPedal at 80 RPMs.
qMassage keypad with fingertips
qTest battery voltage or replace with fully
charged 9V alkaline battery
qCheck wire harness for loose connections
at Display Console, Alternator Control
Board, Alternator and Battery
qCheck wire harnesses for damage
qSwitch or replace Display Console
qSwitch or replace Alternator Control Board
qSwitch or replace Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

2
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: DISPLAY CONSOLE INITIALIZES BUT DOESN’T STAY ON
Symptom Probable Cause Corrective Action
Display Console initializes
but doesn’t stay on Loose connection or damaged
harness
Defective Display Console
Defective Alternator Control
Board
Defective Alternator
qReseat Connectors at Display Console,
Alternator Control Board, Alternator and
Battery
qCheck wire harnesses for damage
qSwitch Display Console
qSwitch Alternator Control Board
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

3
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: LIGHTS FLICKER OR FADE IN AND OUT / ERRATIC DISPLAY CONSOLE
Symptom Probable Cause Corrective Action
Lights Flicker or Fade In
and Out / Erratic Display
console
Not pedaling fast enough
Low battery voltage
Loose wire connections
Damaged wire harness
Defective Alternator Control
Board
Defective Aternator
qPedal at 80 RPMs
qCheck battery voltage or replace with a
fully charged 9V alkaline battery.
qReseat connector at Display Console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qSwitch or replace Alternator Control Board
qSwitch or replace Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

4
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: FLASHING PROMPT REMAINS ON
Symptom Probable Cause Corrective Action
Flashing prompt remains
ON Not Pedaling Fast Enough
Not entering acceptable data
Defective Display Console
Defective Alternator Control
Board
qPedal at 80 RPMs
qSee Operation Manual
qSwitch Display Consoles
qSwitch Alternator Control Board
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

5
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: LOADS AT START OF A PROGRAM
Symptom Probable Cause Corrective Action
Loads at start of a program Not pedaling fast enough
Loose wire connections
Damaged wire harness
Alternator output low
Defective Display Console
Defective Alternator Control
Board
Defective Alternator
qPedal at 80 RPMs
qReseat connector at Display Console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qCheck Alternator Output
qSwitch Display Consoles
qSwitch Alternator Control Board
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

6
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: LOADS IN MIDDLE OF A PROGRAM
Symptom Probable Cause Corrective Action
Loads in the middle of a
program Not pedaling fast enough
Loose wire connections
Damaged wire harness
Defective Display Console
Defective Alternator Control
Board
Alternator output low
Defective Alternator
qPedal at 80 RPMs
qReseat connector at display console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qSwitch Display Consoles
qSwitch Alternator Control Board
qCheck Alternator output. Should be 9-10V.
Red probe on output, Black probe on
ground. Pedal and press Start.
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

7
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: KEYS DO NOT RESPOND ( Start button not included )
Symptom Probable Cause Corrective Action
Keys do not respond Entering unavailable programs
May be in cold area
Defective Display Console
Overlay
Defective Display
qSee Operation Manual
qMassage keypad with fingertips to warm
qSee diagnostics on keypad test
qSwitch or replace Display Console
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

8
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: EXERCISE BIKE IS MAKING A LOUD NOISE
Symptom Probable Cause Corrective Action
Exercise bike is making a
loud noise Seat too high. Seatpost is
hitting the frame
Loose or worn crank bearings
Worn or loose drive belt
Sprocket rubbing against
housing
Damaged crank bearings
Loose or damaged chain
Alternator/flywheel assembly
damaged or worn
Worn freewheel Gear
qAdjust seat height
qAdjust or replace crank bearings
qTighten the drive belt. It should have 1/4”
(6mm) maximum play
qReplace worn drive belt
qTighten crank nut
qReplace worn crank bearings
qReplace chain
qReplace Alternator/flywheel assembly
qReplace freewheel gear and pulley
bearings
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

9
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: LEVEL CHANGES DURING PROGRAM
Symptom Probable Cause Corrective Action
Level Changes During
Program Not pedaling fast enough
Loose wire connections
Damaged wire harness
Cuts or depressions in Display
Console overlay
Defective Display Console
Defective Alternator Control
Board
Alternator output low
Defective Alternator
qPedal at 80 RPMs
qReseat connector at display console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qReplace overlay/bezel
qSwitch Display Consoles
qSwitch Alternator Control Board
qCheck Alternator output. Should be
9-10V. Red probe on output, Black probe
on ground. Pedal and press Start.
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

10
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: DIFFICULT TO PEDAL: DISPLAY IS OFF
Symptom Probable Cause Corrective Action
Difficult to pedal: Display is
off Left crank nut too tight
Drive belt too tight
Defective freewheel gear
Defective crank bearings
qLoosen left crank nut 1/16 turn
qLoosen drive belt tension. There should
be 1/4” (6mm) maximum play
qIf user can not pedal backwards, replace
the freewheel gear
qReplace crank bearings
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

11
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: TOO EASY TO PEDAL
Symptom Probable Cause Corrective Action
Too easy to pedal Workout level too low
Not Pedaling at 80 RPMs
Drive belt too loose
Chain too loose
Loose wire connections
Damaged wire harness
Defective Display Console
Defective Alternator Control
Board
Alternator has incorrect voltage
output
Defective Alternator
qChoose higher workout level
qPedal at 80 RPMs
qTighten drive belt
qReplace chain
qReseat connector at display console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qSwitch Display Consoles
qSwitch Alternator Control Board
qCheck Alternator output. Should be
9-10V. Red probe on output, Black probe
on ground. Pedal and press Start.
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

12
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: TENSION STAYS THE SAME
Symptom Probable Cause Corrective Action
Pedal tension stays the
same Workout level too low
Not Pedaling at 80 RPMs
Drive belt too loose
Chain too loose
Loose wire connections
Damaged wire harness
Defective Display Console
Defective Alternator Control
Board
Alternator has incorrect voltage
output
Defective Alternator
qChoose higher workout level
qPedal at 80 RPMs
qTighten drive belt
qReplace chain
qReseat connector at display console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qSwitch Display Consoles
qSwitch Alternator Control Board
qCheck Alternator output. Should be
9-10V. Red probe on output, Black probe
on ground. Pedal and press Start.
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

13
Lifecycle 3500, 4500, 5500 Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: WILL NOT PEDAL FORWARD
Symptom Probable Cause Corrective Action
Will not pedal forward Defective freewheel gear
Drive belt too tight
Chain has frozen link(s)
Left crank nut too tight
Crank bearings worn or rusted
qFreewheel gear should rotate backward
freely, if not replace It.
qLoosen drive belt . Belt should have a 1/4”
(6mm) maximum play.
qReplace chain.
qLoosen crank nut by 1/16 turn.
qReplace crank bearings.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
Lifecycle 3500, 4500, 5500 Series Exercise Bikes

14
TROUBLESHOOTING GUIDE
Symptom: FLASHING PROMPT GOES OFF WHEN START BUTTON IS RELEASED
Symptom Probable Cause Corrective Action
Flashing prompt goes off
when start button is
released
Workout level too low
Not Pedaling at 80 RPMs
Drive belt too loose
Chain too loose
Loose wire connections
Damaged wire harness
Defective Display Console
Defective Alternator Control
Board
Alternator has incorrect
voltage output
Defective Alternator
qChoose higher workout level
qPedal at 80 RPMs
qTighten drive belt
qReplace chain
qReseat connectors at Display Console,
Alternator Control Board, Alternator and
Battery
qCheck wire harness for damage
qSwitch Display Consoles
qSwitch Alternator Control Board
qCheck Alternator output. Should be
9-10V. Red probe on output, Black probe
on ground. Pedal and press Start.
qSwitch Alternator
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

15
Lifecyle 3500, 4500, 5500 Series Exercise Bikes
NOTES:

16
Lifecyle 3500, 4500, 5500 Series Exercise Bikes
NOTES: