Life Fitness Arc Trainer User manual

Life Fitness Arc Trainer
Service Manual
REV August 30, 2022

Corporate Headquarters
10601 W Belmont Ave, Franklin Park, IL 60131 • U.S.A.
847.288.3300 • FAX: [phone]
Service phone number: 800.351.3737 (toll-free within U.S.A., Canada)
Global Website: www.lifefitness.com
International Offices
AMERICAS
North America
Life Fitness, LLC
10601 W Belmont Ave
Franklin Park, IL 60131 U.S.A.
Telephone: [phone]
Service Email:
customersupport@lifefitness.com
Sales/Marketing Email:
commercialsales@lifefitness.com
United Kingdom
Life Fitness UK LTD
Queen Adelaide
Ely, Cambs, CB7 4UB
Telephone: General Office (+44)
1353.666017
Customer Support (+44) 1353.665507
Service Email: uk.support@lifefitness.com
Sales/Marketing Email: life@lifefitness.com
All Other EMEA Countries and Distributor
Business EMEA*
Life Fitness Atlantic BV
Bijdorpplein 25-31
2992 LB Barendrecht
THE NETHERLANDS
Telephone: [phone]
Service Email:
EMEAServiceSupport@lifefitness.com
Brazil
Life Fitness Brasil
Av. Rebouças, 2315
Pinheiros
São Paulo, SP 05401-300
BRAZIL
SAC: 0800 773 8282 option 2
Telephone: [phone] option 2
Service Email: suportebr@lifefitness.com
Sales/Marketing Email:
vendasbr@lifefitness.com
Germany, Austria, and Switzerland
Life Fitness Europe GMBH
Neuhofweg 9
85716 Unterschleißheim
GERMANY
Telephone:
+49 (0) 89 / 31775166 Germany
+43 (0) 1 / 6157198 Austria
+41 (0) 848 / 000901 Switzerland
Service Email:
kundendienst@lifefitness.com
Sales/Marketing Email:
vertrieb@lifefitness.com
ASIA PACIFIC (AP)
Japan
Life Fitness Japan, Ltd
4-17-33 Minami Aoyama 1F/B1F
Minato-ku - Tokyo 107-0062
Japan
Telephone: [phone]
Fax: [phone]
Service Email: service.lfj@lifefitness.com
Sales/Marketing Email:
sales@lifefitnessjapan.com
Latin America and Caribbean*
Life Fitness, LLC
10601 W Belmont Ave
Franklin Park, IL 60131 U.S.A.
Telephone: [phone]
Service Email:
customersupport@lifefitness.com
Sales/Marketing Email:
commercialsales@lifefitness.com
Spain
Life Fitness IBERIA
C/Frederic Mompou 5,1º1ª
08960 Sant Just Desvern Barcelona
SPAIN
Telephone: [phone]
Service Email:
servicio.tecnico@lifefitness.com
Sales/Marketing Email:
info.iberia@lifefitness.com
Hong Kong
Life Fitness Asia Pacific LTD
26/F, Global Trade Square
21 Wong Chuk Hang Road
Wong Chuk Hang
Hong Kong
Telephone: [phone]
Fax: [phone]
Service Email: service.hk@lifefitness.com
Sales/Marketing Email:
hongkong.sales@lifefitness.com
EUROPE, MIDDLE EAST, and AFRICA (EMEA)
Netherlands and Luxemburg
Life Fitness Atlantic BV
Bijdorpplein 25-31
2992 LB Barendrecht
THE NETHERLANDS
Telephone: [phone]
Service Email:
service.benelux@lifefitness.com
Sales/Marketing Email:
marketing.benelux@lifefitness.com
Belgium
Life Fitness Benelux NV
Parc Industrial de Petit-Rechain
4800 Verviers
BELGIUM
Telephone: [phone]
Service Email:
service.benelux@lifefitness.com
Sales/Marketing Email:
marketing.benelux@lifefitness.com
All Other Asia Pacific countries and distributor
business Asia Pacific*
Life Fitness Asia Pacific LTD
26/F, Global Trade Square
21 Wong Chuk Hang Road
Wong Chuk Hang
Hong Kong
Telephone: [phone]
Fax: [phone]
Service Email: service.hk@lifefitness.com
Sales/Marketing Email:
hongkong.sales@lifefitness.com
*Also check www.lifefitness.com for local representation or distributor/dealer
Page 1 of 79

User and Service Documents Link
https://lifefitness9512.zendesk.com/hc/en-us
https://www.lftechsupport.com/web/document-library/documents
Additional information is available online using the links above.
. 
点击上面的链接可在线获取更多信息。
Flere oplysninger er tilgængelige online gennem linket ovenfor.
Bijkomende informatie is online beschikbaar via bovenstaande link.
Vous trouverez plus d'informations en ligne à l'aide du lien ci-dessus.
Zusätzliche Informationen finden Sie online über den oben angegebenen Link.
Ulteriori informazioni sono disponibili online utilizzando il link sopra riportato.
追加情報は上記リンクを使用してオンラインで利用可能です。
상기 링크를 통해 온라인에서 추가 정보를 볼수있습니다.
Informações adicionais estão disponíveis on-line, através do link acima.
Дополнительная информация доступна винтернете по ссылке, указанной выше.
Mediante el enlace anterior podrá acceder a información adicional en línea.
Ytterligare information finns online genom att använda länken ovan.
İnternet üzerinden daha fazla bilgi edinmek için yukarıdaki bağlantıyı kullanabilirsiniz.
.  
Informazio osagarria eskuragarri dago goiko estekaren bidez.
Допълнителна информация можете да намерите онлайн, като използвате връзката по-горе.
Mitjançant l'enllaç anterior podreu accedir a informació addicional en línia.
使用上面的連結線上提供額外資訊。
Dodatne informacije možete pronaći na internetu sljedeći vezu iznad.
ከላይ የተቀመጠውን አገናኝ(ሊንክ) በመጠቀም መረጃዎች ኦንላይን ያገኛሉ
Lisätietoja on saatavissa verkosta käyttämällä yllä olevaa linkkiä.
Wubetumi anya nsɛm afoforo aka ho wɔwɛbsait so denam asɛm a ɛwɔatifi hɔa wubemia so so.
Πρόσθετες πληροφορίες είναι διαθέσιμες ονλάιν χρησιμοποιώντας το σύνδεσμοπαραπάνω.
.עדימףסונרשפאלבקלטנרטניאבתועצמאברושיקהליעל
További információ elérhető online, a fenti hivatkozás segítségével.
Viðbótarupplýsingar eru fáanlegar á netinu með því að smella á tengilinn hér fyrir ofan.
Plus indicium per superum situm potes invenire.
      .
Ytterligere informasjon er tilgjengelig på nettet via linken ovenfor.
Dodatkowe informacje są dostępne online pod powyższym odnośnikiem.
Informações adicionais estão disponíveis online a usar o link acima.
Informații suplimentare sunt disponibile online, utilizând link-ul de mai sus.
Dodatne informacije dostupne su na mreži putem gornjeg linka.
Ďalšie informácie sú dostupné online na vyššie uvedenom odkaze.
Page 2 of 79

Table of Contents
Safety
Safety Instructions......................................................... 4
Introduction
Using this Manual.......................................................... 6
Customer Support Contact Information.....................6
Online References.........................................................6
Related Products........................................................... 6
Maintenance
Preventive Maintenance Tips.......................................7
Approved and Compatible Cleaners......................... 7
Maintenance Schedule................................................. 7
Drive Belts...................................................................... 8
Theory of Operation
Overview...................................................................... 10
Battery...........................................................................10
Belts.............................................................................. 10
Console........................................................................ 10
Incline............................................................................10
Power Supply...............................................................10
Pulleys...........................................................................10
Resistance Control Board (RCB)................................11
How To's
Knowledge Base..........................................................12
Battery Replacement...................................................12
Brake Generator Assembly Replacement................15
Contact Heart Rate Grips Replacement - Lower
Body.........................................................................22
Contact Heart Rate Grips Replacement - Total
Body.........................................................................25
Display Cable Replacement.......................................27
Handle Assembly Replacement................................ 32
Linkage Rods Replacement....................................... 35
Primary Drive Belt Replacement................................37
Pulley and Crank Shaft Replacement........................44
Front Foot Plate Arm Replacement.......................... 51
Rear Foot Plate Arm Replacement............................59
Troubleshooting
Knowledge Base..........................................................67
Troubleshooting the Polar®Heart Rate Chest
Strap........................................................................ 67
Troubleshooting the Lifepulse™System Sensors... 67
Incline Not Working....................................................68
Software
Refer to Console Service Manual.............................. 69
Diagnostics
Refer to Console Service Manual.............................. 70
Error code list
Refer to Console Service Manual.............................. 71
Network Information
Refer to Console Service Manual.............................. 72
Schematics
Online References.......................................................73
Advanced Schematic.................................................. 74
Basic Schematic...........................................................75
LED Chart
Resistance Control Board LED's................................76
Glossary
Connectors...................................................................77
Heart Rate Sensor / HR Sensor.................................. 77
LED................................................................................77
Levelers.........................................................................77
Lifepulse™.................................................................... 77
Polar Receiver..............................................................77
RCB................................................................................77
Warranty
What is Covered..........................................................78
Who is Covered...........................................................78
How Long It is Covered.............................................. 78
Who Pays Transportation and Insurance For
Service.....................................................................78
What We Will Do To Correct Covered Defects.......78
What is Not Covered.................................................. 78
What You Must Do...................................................... 78
How to Get Parts and Service.................................... 78
Exclusive Warranty...................................................... 78
Changes in Warranty Not Authorized...................... 79
Effects of State Laws....................................................79
Warranty Information..................................................79
© Copyright , Life Fitness, LLC. All Rights Reserved. Life Fitness, Hammer Strength, Cybex, ICG and SCIFIT are registered trademarks of Life
Fitness, LLC and its affiliated companies and subsidiaries. Disclaimer: Images and specifications are current as of the date of publication
and are subject to change.
10601 W Belmont Ave, Franklin Park, IL 60131 • 847-288-3300 •
www.lifefitness.com • August 30, 2022 •
Page 3 of 79

1. Safety
Safety Instructions
Read all instructions before use.
Please take special note of the following safety instructions and important points prior to choosing a location and
beginning assembly of the product.
WARNING: Health-related injuries may result from incorrect or excessive use of exercise equipment. Life
Fitness Family of Brands STRONGLY recommends seeing a physician for a complete medical exam before
undertaking an exercise program, particularly if the user has a family history of high blood pressure or heart
disease, is over the age of 45, smokes, has high cholesterol, is obese, or has not exercised regularly in the past
year. If, at any time while exercising, the user experiences faintness, dizziness, pain, or shortness of breath, he or
she must stop immediately.
WARNING: To reduce the risk of burns, fire, electric shock, or injury, it is imperative to connect each product to
a properly grounded electrical outlet.
WARNING: Heart rate monitoring systems may be inaccurate. Over exercising may result in serious injury or
death. If you feel faint, stop exercising immediately.
WARNING: Do not use for stretching and do not attach straps or other devices.
WARNING: Keep batteries out of reach of children.
Some chest straps may contain a removable battery.
• Swallowing may lead to serious injury in as little as 2 hours or death, due to chemical burns and potential
perforation of the esophagus.
• If you suspect your child has swallowed a battery, immediately call your local poison control for fast, expert
advice.
• Examine devices and make sure the battery compartment is correctly secured, e.g. that the screw or other
mechanical fastener is tightened. Do not use if compartment is not secure.
• Dispose of used button batteries immediately and safely. Flat batteries can still be dangerous.
• Tell others about the risk associated with button batteries and how to keep their children safe.
WARNING: Ensure that there is at least 23.6" (0.6 m) of clearance behind the product and at least 12" (30 cm)
on the sides.
WARNING: The product is not equipped with a free-wheeling feature. Therefore, it cannot be stopped
immediately.
WARNING: Moving parts and fall hazard.
• To avoid serious injury wait until foot plates come to a complete stop before getting off unit.
• The moving parts cannot be stopped immediately, the unit is not equipped with a free wheel.
WARNING: This product can expose you to chemicals including Di-2-ethylhexyl-phthalate, which is known to
the State of California to cause cancer and birth defects or other reproductive harm. For more information go to
http://www.P65Warnings.ca.gov
DANGER: To reduce the risk of electrical shock or injury from moving parts, always unplug product before
cleaning or attempting any maintenance activity.
Keep all body parts, loose clothing, shoelaces, and towels away from moving parts.
•The individual human power required to perform an exercise may be different than the mechanical power
displayed on the product.
• Use caution when mounting or dismounting the product. Before mounting, use the moving arms to bring the foot
plate nearest to you to the lowest position. Use the stationary handlebars whenever additional stability is required.
While exercising, hold onto the moving arms.
• Never face backward while using the product.
• Do not stand or sit on the rear plastic covers of the product.
• Never operate the product if it has a damaged power cord or electrical plug, or if it has been dropped, damaged,
or even partially immersed in water. Contact Customer Support Services.
• Position the product so that the power cord plug to the wall is accessible to the user. Make sure that the power cord
is not knotted or twisted and that it is not trapped under any equipment or other objects.
• If the electrical supply cord is damaged, it must be replaced by the manufacturer, an authorized service agent, or a
similarly qualified person to avoid a hazard.
Page 4 of 79

• Always follow the console instructions for proper operation.
• This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental
capabilities, or lack of experience or knowledge unless they have supervision or been given instruction concerning
the use of the appliance by a person responsible for their safety.
• This equipment is not intended for use by children. Keep children under the age of 14 away from the machine.
• Do not use this product outdoors, near swimming pools or in areas of high humidity.
• Never operate the product with the air openings blocked. Keep air openings free of lint, hair, or any other
obstructing material.
• Never insert objects into any opening in these products. If an object should drop inside, turn off the power, unplug
the power cord from the outlet, and carefully retrieve it. If the item cannot be reached, contact Customer Support
Services.
• Never place liquids of any type directly on the unit, except in an accessory tray or holder. Containers with lids are
recommended.
• Do not use these products in bare feet. Always wear shoes. Wear shoes with rubber or high-traction soles. Do not
use shoes with heels, leather soles, cleats or spikes. Make sure no stones are embedded in the soles.
• Do not reach into, or underneath, the unit or tip it on its side during operation.
• Do not allow other people to interfere in any way with the user or equipment during a workout.
• Allow LCD consoles to “normalize” with respect to temperature for one hour before plugging the unit in and using.
• Use these products for their intended use as described in this manual. Do not use attachments that have not been
recommended by the manufacturer.
• Free standing equipment shall be installed on a stable and leveled surface.
• Read all warnings on each product prior to starting a workout.
• If warnings are missing or damaged, please contact Customer Support Services immediately for replacement
warning labels. Warning labels are shipped with every product and should be installed before product is used. Life
Fitness Family of Brands is not responsible for missing or damaged warning labels.
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE.
Testing Parameters
Displayed power (Wattage) and speed (Strides Per Minute), were found to meet class A accuracy when compared with
measured power and speed, with adjustable braking positioned in its maximum position, at the following accuracy test
points:
• 25 W, 37 SPM
• 50 W, 52 SPM
• 100 W, 72 SPM
• 150 W, 86 SPM
• 175 W, 92 SPM
• 200 W, 97 SPM
Page 5 of 79

2. Introduction
Using this Manual
Descriptions using the words "left" and "right" refer to the orientation of a user using the product, facing the console.
"Front" is the area of the product with the console. The "Rear" of the product is behind the user.
Customer Support Contact Information
Refer to Corporate Headquarters for contact info.
To speed Customer Support Service’s response, please provide the following information to the customer support
technician:
• Serial number
• Model number
• Part name
• Part number
• Symptom of problem
Serial Number Location
The serial number decal is located on the lower crossbar.
Item Description
1 Serial number decal
2 Lower crossbar
Online References
Detailed Schematics are available online in Parts Manuals:
•https://www.lftechsupport.com access technical documentation and part manuals for Life Fitness, Hammer
Strength, and ICG.
•http://www.lifefitness.com/parts service parts ordering for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG
products along with warranty parts ordering and technician requests.
•https://lfworld.lifefitness.com easy to find Knowledge Base articles with answers to frequently asked questions and
product support documentation for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG.
Related Products
The Life Fitness Arc Trainer uses the following consoles:
Simple base Advanced base
Consoles: Integrity C and Integrity X Consoles: Discover SE3 console, Discover SE3HD
console, Discover ST console
Self powered Requires 24 VDC power supply
Total body has thumb controls Total body has thumb controls
Power supply required for optional TV Different cabling from Cybex Arc Trainer
Page 6 of 79

3. Maintenance
Preventive Maintenance Tips
LIFE FITNESS products are backed by the engineering excellence and reliability of LIFE FITNESS and are one of the
most rugged and trouble-free pieces of exercise equipment on the market today.
NOTE: Safety of the equipment can be maintained only if the equipment is examined regularly for damage or wear.
Keep the equipment out of use until defective parts are repaired or replaced. Pay special attention to parts that are
subject to wear, as outlined below.
NOTE: Pour assurer la sécurité du matériel, il convient de l’inspecter régulièrement afin de déceler tout signe d’usure
ou d’endommagement. N’utilisez pas l’appareil avant d’avoir réparé ou remplacé les pièces défectueuses. Portez une
attention toute particulière aux pièces qui s’usent, comme indiqué ci-dessous.
The following preventive maintenance tips will keep the LIFE FITNESS product operating at peak performance:
• Locate the product in a cool, dry place.
• Clean the display console and all exterior surfaces with an approved or compatible cleaner (see LIFE FITNESS
Approved Cleaners) and a microfiber cloth.
• Long fingernails may damage or scratch the surface of the console; use the pad of the finger to press the selection
buttons on the console.
• Clean the top surface of the foot plates regularly.
• Clean the housing and moving arms thoroughly on a regular basis.
Approved and Compatible Cleaners
Two preferred cleaners have been approved by reliability experts: PureGreen 24 and Gym Wipes. Both cleaners will
safely and effectively remove dirt, grime and sweat from equipment. PureGreen 24 and the Antibacterial Force
formula of Gym Wipes are both disinfectants that are effective against MRSA and H1N1.
PureGreen 24 is available in a spray which is convenient for gym staff to use. Apply the spray to a microfiber cloth and
wipe down the equipment. Use PureGreen 24 on the equipment for at least 2 minutes for general disinfection
purposes and at least 10 minutes for fungus and viral control.
Gym Wipes are large, durable pre-moistened wipes to use on the equipment before and after workouts. Use Gym
Wipes on the equipment for at least 2 minutes for general disinfection purposes.
Contact Customer Support Services to order these cleaners (1-800-351-3737 or email:
customersupport@lifefitness.com).
Mild soap and water or a mild non-abrasive household cleaner can also be used to clean the display and all exterior
surfaces. Use a soft microfiber cloth only. Apply the cleaner to the microfiber cloth before cleaning. DO NOT use
ammonia or acid based cleaners. DO NOT use abrasive cleaners. DO NOT use paper towels. DO NOT apply cleaners
directly to the equipment surfaces.
Maintenance Schedule
Item Weekly Monthly Annually
Console Overlays Clean Inspect
Bottle Holders / Accessory Trays Clean Inspect
Console Mounting Bolts Inspect
Drive Belts Inspect
Hardware Inspect
Frames Clean Inspect
Plastic Covers Clean Inspect Inspect
Lifepulse Sensors Clean / Inspect
Foot Plates Clean Inspect
Leg Levelers Inspect / Adjust
Page 7 of 79

Drive Belts
Remove Front Access Cover
1. Remove screws securing front access cover using a Phillips screwdriver.
Description Qty.
1Screw 4
2Front Access Cover 1
2. Remove access cover.
WARNING: Burn hazard.
Do not touch flywheel until cool.
Inspect Drive Belts
There are two drive belts that may become loose, worn or cracked.
Unless the belts have been removed and not replaced properly, it is unlikely the belts will come loose or need to be
re-tensioned.
Item Description Qty.
1Primary Drive Belt 1
2Secondary Drive Belt 1
If a belt has cracks or appears worn, it must be replaced immediately by a qualified service technician.
Primary Belt
The wider of the two belts. It has grooves that keep it aligned on the large upper pulley.
Secondary Belt
The narrower of the two belts. It has grooves that keep it aligned on the flywheel's drive pulley.
Install Access Cover
CAUTION: Do not over tighten screws.
1. Replace and tighten the two upper screws using a Phillips screwdriver.
2. Replace and tighten the two lower screws using a Phillips screwdriver.
Page 8 of 79

3. Test unit for proper operation.
Page 9 of 79

4. Theory of Operation
Overview
The drive system is a dual stage drive system. The articulating handles, if equipped, connect to the front foot plate
arms via linkage rods. The front foot plate arms connect to crank arms via linkage rods. Fore-aft movement of the
handles and footplates cause the crankshaft to rotate as a result of crank arm movement.
The primary drive pulley is located on the crank shaft and drives a pulley on the lower pulley shaft via the primary drive
belt. A second pulley on the lower pulley shaft transmits rotational power to the brake / generator via the secondary
drive belt.
The brake / generator serves two functions:
• The rotating generator provides power to the Arc Trainer
• The brake provides resistance to the user’s motion
Some Arc Trainers are self-powered, in other words generator powered, but do have an optional 12 VDC power
supply for low or infrequent use environments. All Arc Trainers have an internal 12 VDC battery that charges during
use to provide extra power for the incline system. Arc Trainers with higher console power needs require an external 24
VDC power supply to augment the Arc Trainer’s generator power.
Battery
The unit is designed with a 12 volt Lead-Acid rechargeable battery. The battery will recharge during regular operation
of unit or when the optional power adapter is plugged in. The display will indicate dashes in the incline display if the
battery fails to provide enough energy. The unit will still function normally other than the disabling of the incline
feature. If the battery is completely discharged, the workout review will also be truncated if the user is not striding
during the time period.
Belts
The belts are the means by which the rotational force in each of the pulleys is transferred. Both of the belts are poly-v
drive belts which, when put in tension on the pulleys, provide a connection for the pulleys and component that
receives their rotational force.
Console
The console tracks the time, distance traveled, level of resistance, level of incline, and speed of the Arc Trainer when it
is in use. The watt output is also calculated based on the resistance level manually set by the user. The heart rate will
also appear if the user is wearing a heart rate detecting device or gripping the Lifepulse™grips.
Incline
In addition to resistance to motion provided by the brake / generator, the Arc Trainer has an incline motor that allows
the user to adjust between Glide, Stride, and Climb settings to adjust intensity and target muscle groups being
worked. The Arc Trainer’s battery is essential for proper incline function. The default setting for an Arc Trainer at rest is
incline setting 6. Setting 6 is the transition point between Glide and Stride, decreasing the value lessens the Glide
intensity, increasing the value transitions the Arc Trainer into the Stride region and eventually the Climb region of
operation.
Power Supply
The Life Fitness Arc Trainer with a ST, SE3, or SE3HD console always require a 24 VDC power supply.
The Life Fitness Arc Trainer with a C or X console are self powered, but can use an optional 12 VDC 5 AMP Power
Supply (same used with TV).
Pulleys
The pulleys are mounted to the crank shaft connected to the frame via pillow blocks and the lower pulley shaft bolted
to the frame. All pulleys reside inside the front shrouding. As the user moves the foot plates and handles, Crank arms
which are connected to the front foot plate arms, pivot around at its connection to the Crankshaft. The Crank Pulley
rotates due to the rotational force supplied to it from the Crankshaft. The rotational force from the Crank Pulley is
transferred to the smaller Intermediate Pulley. This reduction in size results in an increase in rotations for the
Intermediate Pulley which is important for the brake / generator.
Page 10 of 79

Resistance Control Board (RCB)
The RCB contains the Arc Trainer’s fundamental electronics and resides inside the front shrouding behind a metal
cover. The RCB inputs power from the generator and / or attached power supply and converts it to voltages needed to
run the electronics, apply braking force and operate the incline motor. Additionally, the RCB tracks user’s exercising
speed by interpreting speed from the generator output. The RCB bidirectionally communicates with the display to
accept user settings and to feed the display with usage information such as expended calories.
RCB Connectors
Page 11 of 79

5. How To's
Knowledge Base
See Knowledge Base for more detailed information.
Battery Replacement
Tools Required:
• Phillips screwdriver
• Needle nose pliers
Remove front access cover
1. Remove screws securing front access cover using a Phillips screwdriver.
Item Description Qty.
1Screw 4
2Front access cover 1
2. Remove access cover.
WARNING: Burn hazard.
Do not touch flywheel until cool.
Remove control board assembly
1. Remove controller cover using a Phillips screwdriver.
Item Description Qty.
1Cable tie 1
2Battery cable 1
3Incline motor cable 1
4Controller cover 1
5Control Board 1
6Screw 1
2. Disconnect all cables from control board.
3. Remove screws securing control board in place using a Phillips screwdriver.
Page 12 of 79

Remove battery
1. Remove screw securing battery bracket using a Phillips screwdriver.
Item Description Qty
1 Battery 1
2 Screw 1
3 Battery bracket 1
4 Red (+) and Black (-) battery terminals 2
2. Remove red (+) and black (-) female terminals from battery. Pull at terminal and not wire.
NOTE: Needle nose pliers may be needed if unable to remove terminal by hand.
3. Remove battery.
NOTE: Dispose of batteries safely after replacement or before unit disposal.
Install battery
1. Connect battery cables to red (+) and black (-) female terminals on battery.
Item Description Qty
1 Battery 1
2 Screw 1
3 Battery bracket 1
4 Red (+) and Black (-) battery terminals 2
NOTE: Make sure battery cables are connected properly.
2. Install screw securing battery with battery bracket using a Phillips screwdriver.
Install control board assembly
1. Place control board assembly in position on frame.
2. Install the screws securing the control board assembly in place using a Phillips screwdriver.
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3. Plug all cables into control board.
Item Description Qty.
1Cable tie 1
2Battery cable 1
3Incline motor cable 1
4Controller cover 1
5Control Board 1
6Screw 1
Install front access cover
Do not over tighten screws.
1. Place front access cover in place.
Item Description Qty.
1Screw 4
2Front access cover 1
2. Install screws using a Phillips screwdriver.
Complete Installation
Operate unit at all levels to verify proper operation.
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Brake Generator Assembly Replacement
Tools Required:
• 3/16” Allen wrench
• 5/16" Allen wrench
• Phillips screwdriver
• Long Phillips screwdriver
• 1/2” Socket wrench
• 9/16” Socket wrench
• Loctite®#242, Blue
• Loctite®#271, Red
• Straight edge
• Torque wrench
• Clean cloth (2)
Disconnect Power Source
Unplug power cord from power outlet.
WARNING: Shock and electrocution hazard.
• Unplug unit and let sit 10 minutes before cleaning or performing maintenance.
• Electrical charge can remain in unit after unplugging.
• Keep water and liquids away from electrical parts.
Remove front access cover
1. Remove screws securing front access cover using a Phillips screwdriver.
Item Description Qty.
1Screw 4
2Front access cover 1
2. Remove access cover.
WARNING: Burn hazard.
Do not touch flywheel until cool.
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Remove linkage rods
1. Remove socket head cap screw (SHCS), flat washer, cap and spacer securing linkage rod using a 3/16” Allen
wrench.
Item Description Qty.
1Screw, SHCS .250-20 x .75 1
2Flat washer 1
3Cap 1
4Spacer 1
5Linkage rod 1
2. Lay linkage rod down on frame. Place a clean cloth in between linkage rod and frame to prevent scratches.
3. Repeat steps 1 and 2 for other linkage rod.
Remove crank covers
1. Remove both screws securing crank cover using a Phillips screwdriver.
Item Description Qty.
1Screw 2
2Crank cover 1
3Crank arm 1
4Flush mount 1
5Crank shaft 1
2. Remove crank cover.
3. Repeat steps for other crank cover.
Remove shrouds
1. Remove seven screws securing left shroud in place using a long Phillips screwdriver.
Item Description Qty.
1Screw 7
2Left shroud 1
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2. Remove three screws securing right shroud in place using a long Phillips screwdriver.
3. Remove both shrouds.
Remove Brake Generator
1. Unplug brake generator from resistance control board.
2. Loosen lower pivot mounting bolts (HHCS) using a 1/2” socket wrench. This will loosen tension on primary and
secondary belts.
Item Description Qty
1 Lower pivot mounting bolt (HHCS) 2
2 Primary drive belt 1
3 Drive pulley 1
4 Secondary drive belt 1
3. Remove lower pivot mounting bolt (HHCS), lock washer, and flat washer from secondary drive belt side.
Item Description Qty
1 Lower pivot mounting bolt (HHCS) 1
2 Lock washer 1
3 Flat washer 1
4 Lower pulley shaft 1
5 Secondary drive belt 1
4. Remove secondary drive belt from lower pulley shaft.
5. Remove four bolts and washers securing brake generator to frame using a 5/16" Allen wrench..
Item Description Qty
1 Brake Generator 1
2 Spacer 1
3 Washer 4
4 Bolt 4
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6. Remove brake generator and spacer from frame.
Install Brake Generator
1. Apply Red Loctite®#271 to four bolts.
Item Description Qty
1 Brake Generator 1
2 Spacer 1
3 Washer 4
4 Bolt 4
2. Align spacer with brake generator.
3. Install four bolts and washers securing brake generator to frame using a 5/16" Allen wrench. Torque to 120 lb-in.
4. Plug brake generator into resistance control board.
5. Install secondary drive belt onto lower pulley shaft.
Item Description Qty
1 Lower pivot mounting bolt (HHCS) 1
2 Lock washer 1
3 Flat washer 1
4 Lower pulley shaft 1
5 Secondary drive belt 1
6. Install lower pivot mounting bolt (HHCS), lock washer, and flat washer to secondary drive belt side.
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