Life Fitness FS4 User manual

FS4 and FS6 Cross-Trainers
Service Manual
REV

Corporate Headquarters
Columbia Centre III, 9525 West Bryn Mawr Avenue, Rosemont, Illinois 60018 • 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, Inc.
Columbia Centre III
9525 West Bryn Mawr Avenue
Rosemont, IL 60018 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*
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, Inc.
Columbia Centre III
9525 West Bryn Mawr Avenue
Rosemont, IL 60018 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
32/F, Global Trade Square
21 Wong Chuk Hang Road
Hong Kong
Telephone: [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*
32/F, Global Trade Square
21 Wong Chuk Hang Road
Hong Kong
Telephone: [phone]
Fax: [phone]
Service Email: Service.AP@lifefitness.com
Sales/Marketing Email:
Marketing.HK.Asia@lifefitness.com
*Also check www.lifefitness.com for local representation or distributor/dealer
Page 1 of 39

Table of Contents
Introduction
Using this Manual.......................................................... 3
Maintenance
Maintenance Schedule................................................. 4
Theory of Operation
Electric Brake Control................................................... 5
Servo Motor....................................................................5
Stride Adjust...................................................................5
Mechanical Eddy Current Brake..................................5
Detailed Operation....................................................... 5
How To's
Knowledge Base............................................................7
Cup Holder.....................................................................7
Console...........................................................................8
Console Mounting Bracket........................................ 10
Cup Holder Bracket.................................................... 12
Ergo Bar Assembly......................................................13
Upright Covers............................................................ 14
Pedal Lever Clevis Covers..........................................15
User Handle................................................................. 16
Resistance Servo Motor..............................................17
Lower Control Board.................................................. 19
Eddy Current Brake Mechanism................................21
Servo Calibration.........................................................25
Calibrate Eddy Current Brake and Servo Motor..... 27
Troubleshooting
Electrical....................................................................... 31
Mechanical................................................................... 32
ECB LED's.....................................................................33
Reed Switch..................................................................34
Schematics
FS4 Schematic............................................................. 35
FS6 Schematic............................................................. 36
Glossary
Connectors...................................................................37
Display Console Board...............................................37
Eddy Current................................................................37
EEPROM....................................................................... 37
Heart Rate Sensor / HR Sensor.................................. 37
LCD............................................................................... 37
LED................................................................................37
Levelers.........................................................................37
Lifepulse™.................................................................... 37
PCB................................................................................37
Polar Receiver.............................................................. 37
Reed Switch..................................................................37
RPM............................................................................... 37
Servo Motor................................................................. 37
Warranty
What is Covered..........................................................38
Who is Covered...........................................................38
Who Pays Transportation and Insurance For
Service.....................................................................38
What We Will Do To Correct Covered Defects.......38
What is Not Covered.................................................. 38
What You Must Do...................................................... 38
User Manual................................................................. 38
Product Registration................................................... 38
How to Get Parts and Service.................................... 38
Effects of State Laws....................................................38
Changes in Warranty Not Authorized...................... 38
Effects of State Laws....................................................39
Warranty Information..................................................39
© Copyright 2018, 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. Brunswick and related trademarks used under license from Brunswick
Corporation.
Columbia Center III - 9525 West Bryn Mawr Ave., Rosemont, IL 60018 • 847-288-3300
www.lifefitness.com • • 2018
Page 2 of 39

1. Introduction
Using this Manual
This service manual provides safe and efficient test and service procedures.
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.
Page 3 of 39

2. Maintenance
Maintenance Schedule
Item Weekly Monthly Biannually
Console Overlay Clean Inspect
Bottle Holder Clean Inspect
Console Mounting Bolts Inspect
Frame Clean Inspect
Plastic Covers Clean Inspect
Side Panels Clean Inspect
Lifepulse Sensors Clean / Inspect
Pedals and Straps Clean Inspect
Page 4 of 39

3. Theory of Operation
Electric Brake Control
This PCB interfaces between the console and the servo motor and stride length adjust motors.
Servo Motor
The Servo motor moves the magnets inside the drum to achieve the resistance level the user selected. Also, the servo
motor is sending the magnet position information to the EBC then to the console.
Stride Adjust
The stride adjust motors are controlled by the EBC: (there are a left and right motor)
1. The user selects a desired length.
2. The console sends the EBC a command to move the stride adjust motors.
3. As the motors move they are sending position information to the EBC and then to the console as to the length of
stride.
4. When the user stride is attained, the console sends a stop message to the EBC and the motors stop. There is no
duty cycle on the stride adjust motors as with other cross trainers.
Mechanical Eddy Current Brake
The Eddy Current Brake has a few parts:
1. A drum that rotates when the cross trainer is pedaling.
2. Magnets inside this drum move closer and further away from the drum. This creates the variation in user resistance.
Detailed Operation
The FS4 and FS6 are two models of Rear Entry Cross-Trainers. The FS6 uses electric motors to adjust the stride length.
A Hercules console is the user interface. The Console uses two PCBs.
• Lifepulse™PCB
• Hercules Fit Core®main PCB
The Hercules Fit Core®PCB is the brains of the operation. It provides input and output for the console and standalone
PCBs.
• The Electronic Brake Control ECB
• Adjustment Switches
• The Lifepulse™PCB plugs into the Fit Core®PCB. The Polar®receiver and the Lifepulse™sensors plug into the Life
Pulse PCB.
A 12 Volt External Power Supply provides power through the ECB for Cross Trainer. There isn’t a non-powered model
offered.
The user resistance is provided by an electro-mechanical eddy-current brake. To provide the user resistance the brake
uses the following components.
• Brake Drum
• External Magnet
• Reed switch
• Movable Magnetics inside the brake drum
• Servo Motor
• Cable between the servo motor and brake magnet assembly
The unit goes into an Energy Saving Mode after 5 minutes of inactivity. It will take approximately 50 seconds to wake
up from the Energy Saving Mode. To start the wake-up procedure, pedal and the console will beep. The unit will wake
up automatically and the console will light up.
The external magnet and reed switch provide a RPM signal. The signal is produced when the magnet pass the reed
switch causing it to close. This signal will start the wake-up procedure when waking up from the Energy Saving Mode.
The level switch sets the desired user resistance work out level by moving the servo motor. The servo motor moves the
internal magnets closer or further away from the brake drum diameter. This movement increases or decreases the
Page 5 of 39

level of user resistance respectively. The servo motor movement is calibrated with the console so it precisely controls
the user resistance level. Also, changes in RPM can affect the user resistance. See calibrating Eddy-Current brake in the
“How To's” section of this manual.
The FS6 console has two switches, the left switch adjusts the Stride Length and the right switch adjusts the User
Resistance. The FS4 console has one switch on the right that adjusts the User Resistance. The adjustments must be
calibrated with the console. The “How To's” section of the Service Manual contains the step by step process for making
these calibrations.
Page 6 of 39

4. How To's
Knowledge Base
See Knowledge Base for more detailed information.
Cup Holder
Tools Required:
none
Time:
15 minutes
Remove Cup Holder
1. Place one hand above the cup holder.
2. With the other hand, gently tap the bottom of the cup holder.
3. Lift the cup holder out of the accessory tray.
Install Cup Holder
1. Slide the new cup holder into the accessory tray.
2. Tap the top of the cup holder to seat it properly.
Page 7 of 39

Console
Tools Required:
Phillips screwdriver
Time:
15 minutes
Disconnect power source
Unplug the power cord from the 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 Console
1. Remove four Phillips screws securing the console bracket cover to the console.
Item Description Qty
1 Console 1
2 Grounding screw 1
3 Console bracket cover 1
4 Phillips screw, M5 x 14 mm 4
2. Remove grounding screw.
3. Disconnect the ground wire, base signal, base switches and contact heart rate cable. Note where each cable
connects.
Install Console
1. Connect the ground wire, base signal, base switches and contact heart rate cable.
2. Install the grounding screw.
Item Description Qty
1 Console 1
2 Grounding screw 1
3 Console bracket cover 1
4 Phillips screw, M5 x 14 mm 4
3. Install console using the four Phillips screws that secure the console bracket to the console. Be careful not to pinch
the wires when installing the console.
Page 8 of 39

Complete Installation
Operate the unit at all levels to verify proper operation.
Page 9 of 39

Console Mounting Bracket
Tools Required:
• Phillips screwdriver
• 17 mm Socket wrench with extension
Time:
15 minutes
Disconnect power source
Unplug the power cord from the 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 Rear Console Support Covers
1. Remove upper rear console support cover.
2. Remove lower rear console support cover.
Remove Console
1. Remove four Phillips screws securing the console bracket cover to the console.
Item Description Qty
1 Console 1
2 Grounding screw 1
3 Console bracket cover 1
4 Phillips screw, M5 x 14 mm 4
2. Remove grounding screw.
3. Disconnect the ground wire, base signal, base switches and contact heart rate cable. Note where each cable
connects.
Remove Console Mounting Bracket
Remove and save the two bolts that secure the console mounting bracket.
Install Console Mounting Bracket
Install using the two bolts that secure the console mounting bracket.
IMPORTANT: Be sure that the mounting bracket is positioned so that the console appears straight when installed.
Install Console
1. Connect the ground wire, base signal, base switches and contact heart rate cable.
Page 10 of 39

2. Install the grounding screw.
Item Description Qty
1 Console 1
2 Grounding screw 1
3 Console bracket cover 1
4 Phillips screw, M5 x 14 mm 4
3. Install console using the four Phillips screws that secure the console bracket to the console. Be careful not to pinch
the wires when installing the console.
Install Rear Console Support Covers
1. Install lower rear console support cover.
2. Install upper rear console support cover.
Complete Installation
Operate the unit at all levels to verify proper operation.
Page 11 of 39

Cup Holder Bracket
Tools Required:
• Phillips screwdriver
• 5 mm Allen wrench
Time:
15 minutes
Disconnect power source
Unplug the power cord from the 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 Cup Holder
1. Place one hand above the cup holder.
2. With the other hand, gently tap the bottom of the cup holder.
3. Lift the cup holder out of the accessory tray.
Remove Rear Console Support Covers
1. Remove upper rear console support cover.
2. Remove lower rear console support cover.
Remove Cup Holder Bracket
Remove two screws securing cup holder bracket to upright.
Install Cup Holder Bracket
Install using the two screws securing cup holder bracket to upright.
Install Rear Console Support Covers
1. Install lower rear console support cover.
2. Install upper rear console support cover.
Install Cup Holder
1. Slide the new cup holder into the accessory tray.
2. Tap the top of the cup holder to seat it properly.
Complete Installation
Operate the unit at all levels to verify proper operation.
Page 12 of 39

Ergo Bar Assembly
Tools Required:
• Phillips screwdriver
• 5 mm Allen wrench
Time:
30 minutes
Disconnect power source
Unplug the power cord from the 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 Rear Console Support Covers
1. Remove upper rear console support cover.
2. Remove lower rear console support cover.
Remove Ergo Bar Assembly
1. Remove the four Allen bolts securing the Ergo Bar assembly to the upright.
2. Disconnect all cable connections at the Ergo Bar assembly, identifying where each cable connects. There are
connections for each contact heart rate sensor and one for the activity zone for a total of three connections.
Install Ergo Bar Assembly
1. Connect all cable connections at the Ergo Bar assembly, identifying where each cable connects. There are
connections for each contact heart rate sensor and one for the activity zone for a total of three connections.
2. Install the four Allen bolts securing the Ergo Bar assembly to the upright.
Install Rear Console Support Covers
1. Install lower rear console support cover.
2. Install upper rear console support cover.
Complete Installation
Operate the unit at all levels to verify proper operation.
Page 13 of 39

Upright Covers
Tools Required:
Phillips screwdriver
Time:
15 minutes
Remove Upright Covers
1. Remove four Phillips screws that secure either the left or right upright cover to the frame.
2. Remove the upright cover.
Install Upright Covers
Install upright cover using four Phillips screws that secure either the left or right to the frame.
Page 14 of 39

Pedal Lever Clevis Covers
Tools Required:
Phillips screwdriver
Time:
15 minutes
Remove Pedal Lever Clevis Covers
1. Remove two Pan Head screws that secure the clevis covers to the rocker arms.
Item Description Qty
1 Pan Head screw, M3 x 8 mm 2
2 Front Clevis Cover 2
3 Rear Clevis Cover 2
2. Remove clevis covers.
Install Pedal Lever Clevis Covers
Install clevis covers using two Pan Head screws that secure the clevis covers to the rocker arms.
Item Description Qty
1 Pan Head screw, M3 x 8 mm 2
2 Front Clevis Cover 2
3 Rear Clevis Cover 2
Page 15 of 39

User Handle
Tools Required:
• Phillips screwdriver
• Metric Allen wrench set
Time:
15 minutes
Remove User Handle
1. Remove the deadshaft covers.
Item Description Qty
1 Bolt 4
2 Deadshaft cover 2
3 Screw 2
4 User handle 1
2. Unplug the connectors wrapped around the deadshaft.
3. Remove the four bolts that hold the user handle to the rocker arm.
4. Remove user handle.
Install User Handle
1. Install the four bolts that secure the user handle to the rocker arm. Make sure the cables are not pinched by a boss
when reinstalling the deadshaft covers.
Item Description Qty
1 Bolt 4
2 Deadshaft cover 2
3 Screw 2
4 User handle 1
2. Plug in the connectors wrapped around the deadshaft.
3. Install the deadshaft covers.
Page 16 of 39

Resistance Servo Motor
Tools Required:
• Phillips screwdriver
• Ratchet
• 6 mm Deep socket
Time:
60 minutes
Disconnect power source
Unplug the power cord from the 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 Resistance Servo Motor
1. Remove the screws that secure the left shrouds.
Item Description Qty
1 Left outer shroud 1
2 Left inner shroud 1
3 Screws 6
2. Remove the screw and nut that secure the front of the resistance servo motor to the frame.
Item Description Qty
1 Resistance Servo Motor 1
2 Screws 2
3 Nuts 2
4 Frame 1
3. Rotate the resistance servo motor clockwise. This will make removal of the brake cable easier.
4. Remove brake cable from the resistance servo motor.
5. Remove the remaining screw and nut that secure the resistance servo motor to the frame.
6. Disconnect the resistance servo motor cable from the lower control PCB.
7. Remove the resistance servo motor.
Page 17 of 39

Install Resistance Servo Motor
1. Install the resistance servo motor with the rear screw and nut.
Item Description Qty
1 Resistance Servo Motor 1
2 Screws 2
3 Nuts 2
4 Frame 1
2. Connect the resistance servo motor cable to the lower controller PCB.
3. Power up unit. This procedure sets the initial starting point for the resistance range of the motor.
4. Turn the power switch OFF again.
5. Connect the brake cable to the resistance servo motor.
6. Rotate the resistance servo motor counterclockwise back to its original mounting position.
7. Secure the servo motor to the frame with the front screw and nut.
8. Power up the unit.
9. If the servo motor needs calibrating skip step 10 and proceed to Calibrate the Eddy Current Brake and Servo
Motor.
10. Install the screws that secure the left shrouds.
Item Description Qty
1 Left outer shroud 1
2 Left inner shroud 1
3 Screws 6
Complete Installation
Operate the unit at all levels to verify proper operation.
Page 18 of 39