Life Fitness Elliptical X5i User manual

Models X5i, X5, X3i, and X3 Cross-Trainers
Customer Support Services
SERVICE MANUAL

i
Life Fitness Models X5i, X5, X3i and X3 Cross-Trainers
INTRODUCTION
HOW TO USE SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Cross-Trainer Models X5i, X5, X3i and X3. Illustrations in this service manual
represent typical configurations and may differ slightly from actual equipment. The Service Manual provides safe and
efficient step-by-step service operations. This manual consists of:
TABLE OF CONTENTS
Section I
qTROUBLESHOOTING
Section II
qDIAGNOSTIC
Section III
qHOW TO...SERVICE AND REPAIR
Section IV
qELECTRONICS
Section V
qMISCELLANEOUS
When an operating problem occurs, refer to troubleshooting guides and diagnostic mode to isolate the cause. When
applicable, guides are listed by problem symptom followed with suggestions of probable cause(s).
Once the source of problem is identified, consult the "How To..." guides for recommended repair procedures. "How
To..." sub-sections are organized by replaceable part or assembly name. For convenience, sub-section lists
recommended “Tools Required” to complete specific function. Refer to PARTS IDENTIFICATION to identify proper
name and number of part to order for repair of equipment.
A reproducible FAX order claim form is given in COMMUNICATING BY TELEFACSIMILE for convenient ordering of
service parts.
To order parts, contact Life Fitness Customer Support Services.
Via FAX - 24 hrs. /day, 7 days/week.
Via telephone - Monday through Friday from 8:00 AM to 5:00 PM Central Standard Time.
Via post - At address cited.
To speed Life Fitness Customer Support Services response to your needs, please provide:
•Model number,
•Serial number,
•Symptom, and
•Part name and number
Before installing part, review "How To..." and follow step by step procedures recommended to install part safely and
efficiently. If you have questions or comments please telephone, FAX or, write us. We are:
LIFE FITNESS - CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue; Franklin Park, IL 60131; U.S.A.
Telephone: [phone] Toll-free: 800.351.3737
FAX: [phone] Toll-free: 800.216.8893

ii
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
TABLE OF CONTENTS
SECTION I TROUBLESHOOTING GUIDES PAGE
SLIGHT “BUMP” OR “HITCH”......................................................................................... 3
CLUNKING NOISE........................................................................................................ 3
METALLIC SCRAPING NOISE....................................................................................... 3
NO SPEED READOUT ON CONSOLE VERSION 1......................................................... 3
NO SPEED READOUT ON CONSOLE VERSION 2......................................................... 3
CONSOLE IS NON OPERATIVE.................................................................................... 3
CONSOLE ERRATIC .................................................................................................... 4
DIM OR NOT FUNCTIONING LED SEGMENTS............................................................... 4
BUTTONS NOT FUNCTIONING ON EZ USER PAD......................................................... 4
BUTTONS NOT FUNCTIONING ON CONSOLE ............................................................... 4
ERRATIC HEART RATE................................................................................................ 4
NO HEART RATE READOUT........................................................................................ 4
AT POWER UP #8’SAPPEAR ON CONSOLE AND BEEPS............................................ 4
UNIT DOES NOT CHANGE RESISTANCE...................................................................... 4
SECTION II DIAGNOSTIC MODES (DELUXE MONITOR)
ENTERING DIAGNOSTICS MODE ................................................................................. 3
TOGGLING THROUGH DIAGNOSTIC STATES................................................................ 3
DIAGNOSTIC STATE 1 – SOFTWARE VERSION NUMBER............................................. 4
DIAGNOSTIC STATE 2 – KEYPAD TEST MODE ............................................................ 5
DIAGNOSTIC STATE 3 – DISPLAY TEST MODE ............................................................ 6
DIAGNOSTIC STATE 4 – MAGNET POSITION................................................................ 7
DIAGNOSTIC STATE 5 – RUN TEST.............................................................................. 8
DIAGNOSTIC STATE 6 – SPEED READING TEST.......................................................... 9
DIAGNOSTIC STATE 7 – HEART RATE TEST................................................................ 10
DIAGNOSTIC STATE 8 – EEPROM VERSION NUMBER................................................. 11
DIAGNOSTIC STATE 9 – RUN TIME .............................................................................. 12
DIAGNOSTIC STATE 10 – DISPLAY TEST..................................................................... 13
DIAGNOSTIC STATE 11 – PHOTO SHOOT MODE.......................................................... 14
SECTION II DIAGNOSTIC MODES (STANDARD MONITOR)
ENTERING DIAGNOSTICS MODE ................................................................................. 15
TOGGLING THROUGH DIAGNOSTIC STATES................................................................ 15
DIAGNOSTIC STATE 1 – SOFTWARE VERSION NUMBER............................................. 16
DIAGNOSTIC STATE 2 – DISPLAY TEST MODE ............................................................ 17
DIAGNOSTIC STATE 3 – KEYPAD TEST MODE ............................................................ 18
DIAGNOSTIC STATE 4 – MAGNET POSITION................................................................ 19
DIAGNOSTIC STATE 5 – RUN TEST.............................................................................. 20
DIAGNOSTIC STATE 6 – PHOTO SHOOT MODE ........................................................... 21

iii
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
TABLE OF CONTENTS
SECTION III SERVICE AND REPAIR GUIDE
SERVICE AND REPAIR GUIDE..................................................................................... 3
SIDE SHROUDS .......................................................................................................... 4
PEDAL LEVER COMPONENTS .................................................................................... 8
IDLER AND COUPLER ASSEMBLY COMPONENTS ...................................................... 9
DRIVE BELT AND FLYWHEEL ASSEMBLY - VERSION 1.............................................. 10
DRIVE BELT AND FLYWHEEL ASSEMBLY - VERSION 2.............................................. 11
CONSOLE SUPPORT COLUMN.................................................................................... 12
CONSOLE ASSEMBLY ................................................................................................ 13
REAR WHEELS AND FRONT LEVERERS..................................................................... 14
PEDALS...................................................................................................................... 15
EDDY CURRENT ASSEMBLY - VERSION 1.................................................................. 16
SPEED MOTOR ASSEMBLY - VERSION 2.................................................................... 17
OPTO SENSOR - VERSION 1....................................................................................... 18
REED SWITCH - VERSION 2........................................................................................ 19
SECTION IV ELECTRONIC OVERVIEW AND WIRING BLOCK DIAGRAM PAGE
CABLES VERSION 1.................................................................................................... 3
CABLES VERSION 2.................................................................................................... 4
SECTION V MISCELLANEOUS INFORMATION
SERIAL AND MODEL NUMBERS.................................................................................. 3
PREVENTIVE MAINTENANCE TIPS.............................................................................. 4

1
Life Fitness Models X3i, X3, X5i, and X5 Cross-Trainers
SECTION I
TROUBLESHOOTING GUIDE

2
Life Fitness Models X3i, X3, X5i, and X5 Cross-Trainers
TROUBLESHOOTING GUIDE
Notes:

3
Life Fitness Models X3i, X3, X5i, and X5 Cross-Trainers
TROUBLESHOOTING GUIDE
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Pivot points are not broken in. Remove all clevis covers and loosen all six
bolts that connect links to clevis brackets.
Loosen the nuts a couple of turns so the
machine can still be operated. Operate the
machine a few revolutions to help seat the
pivot points. Retighten the six bolts and
install the clevis covers.
Slight “bump” or “hitch” in
pedal motion.
Levelers are not in contact with the
floor. Levelers must be in contact with the floor. Make sure that the leveler jam nuts are also
properly tightened.
For further assistance, contact Life Fitness
Customer Support Services.
Clunking noise. Damaged washers, retaining rings,
or wave springs. Remove the clevis covers, and check for damaged washers, retaining rings, and wave
springs. If necessary, replace. Remove the
end caps from lower link arm, and then
remove the bolt. Check that retaining ring is
correctly installed. Repeat for all pivot areas.
Metallic scraping noise
occurs in forward or reverse
direction.
Magnet is rubbing on the aluminum
disk or chopper wheel may be
hitting the OPTO Sensor. Applies
only to Version 1 units.
Remove bottom rear shroud (See How To…)
and inspect the position of the magnets to see
if they are rubbing on the aluminum disk. If so,
re-center the OPTO Sensor.
Loose connections between the
OPTO sensor and wiring harness. Verify that the connections between the OPTO sensor and wiring harness are secure.
No speed readout on console.
Applies only to Version 1
units. Chopper wheel is not spinning
between the two tabs of the OPTO
sensor.
Bend the OPTO bracket slightly upwards.
No speed readout on console.
Applies only to Version 2
units.
Magnet missing or faulty reed
switch. Check for missing magnet or replace switch.
Console is out, non-operative. Transformer is not plugged in.
Wiring harness is not connected to
the console.
Pinched wire harnesses.
Verify that the transformer is plugged in.
Verify that the wiring harness is connected to
the console.
Check wiring harness in upright tube or at the
base frame. Verify that the harnesses are
properly connected.
If all connections are correct, replace
transformer, if this does not solve the problem
then replace console.

4
Life Fitness Models X3i, X3, X5i, and X5 Cross-Trainers
TROUBLESHOOTING GUIDE
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Console erratic. Clock within the console not
functioning or the memory chip is
corrupted.
Replace the console.
Dim or not functioning LED
segments on displays. Defective console. Test console in diagnostics. Replace console if necessary.
Buttons not functioning on EZ
user pod. Bad connection between EZ user pod and console. Check connections between EZ user pod and console.
Faulty connection at membrane
switch of console. Check the connection of the membrane switch on the console. Look in the hole in the back of
the console, the connector is on the bottom of
the board assembly and to the right side of
the hole.
Buttons not functioning on
console.
Defective keypad on console. Replace the console.
Erratic heart rate. Receiver mounted incorrectly in
accessory tray. Check that the mounting of the heart rate receiver in the accessory tray is secure and
not loose.
Verify that the receiver has been inserted into
the foam tube.
No heart rate readout. Faulty connection between receiver
and console or faulty receiver. Check connections between the heart rate receiver and the console, or if faulty receiver,
then replace the receiver.
At power up, #8’s appear on
the console and beep sounds
(standard console).
At power up, motor error
appears on console and beep
sounds.
This is a fault condition showing
that the Eddy current or Servo
Motor is not moving or is not moving
to the location it’s supposed to.
Verify that the Eddy current on Version 1 or
Servo Motor on Version 2 is connected to the
wiring harness.
Test Eddy current or Servo Motor in
Diagnostic 4.
If the display is functioning and the numbers
on the left side of the display are changing in
value with each key press but the magnet
does not move and numbers on right side of
display do not appear, then the Eddy current
assembly needs to be replaced.
If no number is shown on the left side of the
display, then the console needs to be
replaced.
After beginning of program,
the unit does not change
resistance, followed by “Motor
Error” message on the
display.
Bad connection at Eddy Current or
faulty Eddy Current. Verify the cable connection at the EDDY current assembly is properly connected. If all
connections are making proper contact, then
replace the EDDY current assembly.

1
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
SECTION II
DIAGNOSTIC MODES

2
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
NOTE

3
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
MESSAGE CENTER
X5i and X3i Deluxe Monitor
Enter
Clear
Pause
Reverse
CT
Down
Cool
Workout
Profile
Quick
Start
P1
P2
P3
P4
P5
P6
P7
X5 and X3 Standard Monitor
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
X5i, X5, X3i, and X3 Display Consoles

4
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
ENTERING DIAGNOSTICS MODE
Diagnostics can only be entered from IDLE mode. Enter Diagnostics by pressing the Pause/Clear button twice, and
then press the Cool Down button, sequence must be completed within 3 seconds, or the monitor returns to IDLE
mode.
Upon entering the Diagnostics mode, the monitor will beep three times before entering Diagnostic State 1.
TOGGLING THROUGH DIAGNOSTIC STATES
Pressing the Enter button will advance to the next Diagnostic State. Diagnostics can only advance.
Once the Last State has been reached, pressing the Enter button again will exit the Diagnostic mode and the
monitor will enter the IDLE mode.

5
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
X.XX
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 1 - Software Version Number
The Calories LED will light and the software version will be displayed in the message center.

6
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 2 - Keypad Test Mode
All LEDs will be off until the keypad buttons are pressed. The following is to be displayed while a button is held
down button. An audible beep will occur with each key press.
BUTTON DISPLAY
Time Ù“1111111111111111”
Time Ú“2222222222222222”
My Workouts “3333333333333333”
Quick Start “4444444444444444”
Workout Profile “5555555555555555”
Level Ù(Main console) “6666666666666666”
Level Ú(Main console) “7777777777777777”
Clear/Pause “8888888888888888”
Cool Down “9999999999999999”
Enter This will advance the monitor the
next diagnostic state #3.
EASY POD NOT SHOWN
Level Ù(on the EZ pod) “AAAAAAAAAAAAAAAA”
Level Ú(on the EZ pod) “BBBBBBBBBBBBBBBB”
CT Reverse “CCCCCCCCCCCCCCCC”
CT Aerobics “DDDDDDDDDDDDDDDD”

7
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 3 - Display Test Mode
In this state the LED patterns will toggle between DISPLAY “A” or “B” as shown.
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
DISPLAY “A”
DISPLAY “B”

8
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 4 - Magnet Position
Upon entering the magnet test, the Cool Down LED is lit. The Message Center displays 3 different numeric values.
The left hand numeric display of 4 digits will show the desired position of the magnets. Numbers will range from 99-
256 on Version 1 Models and from 21-190 on Version 2 Models.
The right hand numeric display of three digits will show a number from 1 to 256. The number displayed is the actual
position of the magnets.
Pressing the Level(Ù) button will activate the motor and move the magnets as to increase resistance. The center
display will show the Resistance setting, the other 2 displays will show the associated desired and actual position of
the magnets.
Pressing the Level(Ú) button will activate the motor and move the magnets as to decrease resistance. The center
display will show the Resistance setting, the other 2 displays will show the associated desired and actual position of
the magnets.
If the system determines that the motor is not responding properly, the display shows Motor Error and beeps to
indicate a motor control error. Power will be removed from the motor in order to prevent damage. Power must be
removed from the console to clear the error by unplugging the unit.
Press Enter to advance.
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
99 199

9
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
X X X
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 5 - A/D Test
Entering diagnostics State 5 indicates current motor position.
Press Enter to advance.

10
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
X
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 6 - Speed Reading Test
Upon entering, the SPEED LED will light. Diagnostic State 6 is used to test the OPTO or RPM Sensor function. To
verify RPM signal, pedal and observe RPM value.
Note: On Version 2 Models, the Speed LED will flash each time a magnet passes the Reed Switch.

11
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
X
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 7 - Heart Rate Test
To verify that the heart rate system is functioning properly, use a polar simulator or a chest strap. If the unit
functions correctly the Heart Rate LED will flash and a heart rate value will be displayed in the Message Center. If
heart rate is not detected, the Heart Rate LED will not be lit.

12
My
Workouts
Quick
Start
Workout
Profiles
Enter
Clear
Cool
Down
Pause
X.XX
Life Fitness Models X5i, X5, X3i, and X3 Cross-Trainers
Diagnostic Mode For Deluxe Monitor
Diagnostic State 8 - EEPROM Version Number
This state displays the EEPROM Version Number. If the EEPROM is not present or fails to function correctly, the
display shows ”EEPROM ERROR”. The Heart Rate % LED will be lit.