Life Fitness Lifecycle 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 )
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]
Serial Number:

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

1
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: "Slowdown". Belt slips during footfall or desired speed is reduced.
Malfunction Probable Cause Corrective Action
Belt slips during footfall
Desired speed is reduced
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).
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

2
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
Faulty rear roller bearings.
Loose deck screws.
Foreign objects may be stuck
underneath the machine.
Lifesprings may be misaligned.
Drive Motor Belt may be worn
or damaged.
Noisy Drive Motor.
Drive Motor Belt may be
squeaking.
Noisy Drive Motor.
Faulty Lift Motor.
Faulty Drive Motor.
High deck and belt friction.
qRun unit for 10 hours of ontime use to
distribute wax evenly
qReplace rear roller assembly.
qTighten deck screws.
qInspect underneath belt and machine.
Remove any debris or accumulation on
debris brush.
qReposition Lifesprings.
qReplace Drive Motor Belt.
qReplace Drive Motor.
qSpray with gear/belt lubricant.
qAlign pulleys if necessary.
qReplace Drive Motor.
qReplace Lift Motor.
qReplace Drive Motor.
qPerform "Power Mode” test.
(See Diagnostics Section)
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: Display Does Not Illuminate or Respond To Input
Malfunction Probable Cause Corrective Action
Display does not illuminate
when machine is powered
on.
Insufficient power source.
Pinched wire connection
Loose connection at Display
Console or Heatsink Control
Board.
Faulty Display Console.
Faulty Heatsink Control Board.
qPlug treadmill into a dedicated 120V, 15
amp circuit
qTurn power ON at switch while pressing
the Speed Down ∇Key and perform
Display test.
qCheck all electrical connections.
qCheck cable in Control Panel for pinched
cable
qSecure connections at Display Console
and Heatsink Control Board.
qReplace Display Console.
qCheck all electrical connections.
qReplace Heatsink Control Board.
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: Unit Resets Randomly
Malfunction Probable Cause Corrective Action
Unit resets randomly Insufficient power source.
Damaged line cord.
Line cord improperly seated in
socket.
Pinched display harness.
Loose connections at heatsink
control board and display.
Safety key not making proper
contact.
Faulty safety key switch
qPlug treadmill into a dedicated 120V,
15 amp circuit.
qReplace line cord.
qInspect power connection at electrical
outlet and at machine for proper contact.
qCheck all display connections.
qVerify cable from Display to handrail
cable is not crimped between (tray)
Control Panel and the handrail.
qReplaced damaged cable.
qSecure connections at heatsink control
board and display.
qPlace safety key in proper position.
qReplace switch.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

5
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: No Power
Malfunction Probable Cause Corrective Action
No Power I/O or On/Off switch.
Insufficient power source.
Safety key at I/O switch
Damaged line cord.
Line cord improperly seated in
socket.
Pinched cable in Control Panel
Power module.
•On/Off switch
•Heatsink
Faulty Display Console.
qIs unit turned on?
qPlug treadmill into a dedicated 120V, 15
amp circuit.
qUsing a meter, verify power at outlet.
qSafety key broken or missing. Replace
safety key.
qReplace line cord.
qInspect power connection at electrical
outlet and at machine for proper contact.
qVerify cable from Display to handrail
cable is not crimped between (tray)
Control Panel and the handrail.
qReplaced damaged cable.
qReplace faulty parts
qOHM ON/OFF switch for continuity.
qUsing 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

6
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
Striding belt needs to be
re-tensioned.
User pushes belt.
Unit is not level.
Belt Skewed
qReplace worn belt.
qRefer to belt tensioning procedure in
operation or service manual.
qCenter belt according to belt centering
technique described in operation
manual.
qLevel treadmill by adjusting leveling
legs.
qReplace front roller bolt with Belt skew
kit.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

7
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Display reads Errors
Malfunction Probable Cause Corrective Action
Belt Moving Error
No ZX
Belt Over Speed
No Blanking
Stop, Stop, Stop
Loose connections at electrical
outlet.
User has overdriven belt.
Loose cable connection.
Opto Sensor not in the proper
position.
Dust or other obstrustion
blocking opto sensor from
reading.
Faulty opto sensor.
User has overdriven belt.
Display has been taken out of
its screen saver mode.
Safety Key not making proper
contact
Faulty Safety Key Switch
qVerify the plug is seated properly in the
electrical outlet.
qReset the unit.
qCheck cable connection at Console
and CPU board.
qAdjust opto sensor.
qClean opto sensor.
qReplace faulty opto sensor.
qReset the unit.
qPower unit off and on to reset
screensaver mode.
qVerify Safety Key is in proper position
qReplace Safety Key Switch in Control
Panel
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: Lift Error
Malfunction Probable Cause Corrective Action
Unit will not incline Line cord in postioned over the
lift leg assembly
Faulty Home Switch.
Faulty Lift Actuator.
Unit will not elevate to 15%
.
qPosition the line cord to its proper
position.
qPerform incline test (See Diagnostics).
qPreform incline test (See Diagnostics).
If unit elevates , check home switch
with an ohm meter. Replace faulty
Home Switch.
qReplace Lift Actuator.
qCheck calibration of Lift Motor.
For Assistance Call:
Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

9
Life Fitness Model 5500HR Treadmill
TROUBLESHOOTING GUIDE
Symptom: Heart Rate System Does Not Respond, Erratic Heart Rate Reading
Symptom Probable Cause Corrective Action
No heart rate or display
reads (No chest strap
detected) Erratic Heart
Rate
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

10
Life Fitness Model 5500HR Treadmill
NOTES:

1
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)

2
Life Fitness Model 5500HR Treadmill
DIAGNOSTIC TESTS ( Continued )
The SPEED DOWN KEY is used for the following testing information:
⇒CHECK THE DISPLAY/KEYPAD FUNCTIONS
⇒REVIEW STATISTICS
⇒IDENTIFY SOFTWARE VERSION
Start with the Life Fitness model 5500HR treadmill turned OFF at the I/O switch.
To advance through this test, use the ENTER KEY.
Power up the unit while holding the SPEED DOWN KEY ∇. All LED’s on the Display Console will light.
Press ENTER once, and Console should begin to scroll through lighting LED’s individually.
Press ENTER a second time and this will bring you to the Keypad test. By pressing each key, a pattern
of LED’s will light. This shows that the button is responding.
Press ENTER a third time and the word Stats will appear in the display readout. Pressing the SPEED UP ∆KEY
will scroll you through the individual statistics. (To scroll back through the statistics, press the SPEED DOWN ∇
KEY)
1st Press Distance LED Lit: Miles
2nd Press Time LED Lit: Motor ON Time (hours)
3rd Press Incline LED Lit: Lift Motor run time
4th Press Cal/Hr LED Lit: Lift Motor (percentage of elevation usage)
5th Press Speed LED Lit: Current limiter Activation
Press ENTER a fourth time and this will give you the Software Version on the treadmill.
For example, the Display will read 2.7EE1.
2.7 Software Version
EEnglish Measurement (miles)
“ M“ would designate Metric Measurement (kilometers)
EEnglish Language
1120V
Press ENTER a fifth time and “Units” appears in the Display readout. Pressing the SPEED UP ∆KEY enables
you to change the unit of measure from ENGLISH/ENGLISH to ENGLISH/METRIC. Pressing the SPEED DOWN
KEY ∇enables you to change the unit from ENGLISH/METRIC to ENGLISH/ENGLISH. Press the CLEAR key 1
time to verify the default after you have chosen a setting.
Press ENTER a Sixth time and “Lang” appears in the Display readout. Pressing the SPEED UP ∆KEY enables
you to change from English to a Foreign language.
At any time in this Test Mode you can go back to the start by pressing the CLEAR/PAUSE KEY.
(Continued)

3
Life Fitness Model 5500HR Treadmill
DIAGNOSTIC TESTS ( Continued )
The INCLINE DOWN KEY ∇is used for the following information.
⇒ELEVATION TEST/ HOME SWITCH
⇒SPEED MODE OPERATION
⇒HEARTRATE MODE OPERATION
Start with the Life Fitness Model 5500HR Treadmill turned OFF at the ON/OFF switch.
Power up the unit while holding the INCLINE DOWN KEY ∇. The Display Console will read Test Mode.
Upon initial entry into the test mode, the left column of the program profile window will have one to two LED’s lit.
The first three LED’s (from the top) of the left column are related to jumpers which are not applicable to any of the
test modes.
The fourth LED from the top indicates the condition of the Opto Speed Sensor. (Normal function of the LED is
that it flashes ON and OFF as the Drive Motor turns during operation).
The fifth LED from the top will inform you if the unit is a 120V or a 220V unit. (When the LED is OFF, the unit is
120V. When the LED is ON, the unit is 220V).
The sixth LED from the top indicates the elevation (Home Switch). When the LED is OFF, the Home Switch is
engaged and the unit is at Zero elevation. When the LED is ON, the Home Switch is disengaged and the unit is
at a non-zero elevation.
The Bottom LED is the Emergency Stop Switch condition. When the LED is ON, the Emergency Stop Switch
is engaged and the unit will operate. When the LED is OFF, the Emergency Stop Switch is disengaged and the
unit will not run.
To test the ELEVATION.
Start with the Treadmill at zero elevation and turned OFF at the ON/OFF switch.
Power up the unit while holding the INCLINE DOWN ∇KEY.
Verify the sixth LED from the top is turned OFF, and the unit is at Zero.
Press the INCLINE UP ∆KEY to start the elevation. The unit will only elevate while the INCLINE UP ∆KEY is
depressed. Note that the sixth led from the top turns ON.
Press the INCLINE DOWN ∇KEY. Note that the sixth LED from the top will turn OFF. The lift will continue to
decline a short while after the LED turns OFF.
To end this test simply turn the treadmill OFF at the ON/OFF switch.
(Continued)

4
Life Fitness Model 5500HR Treadmill
DIAGNOSTIC TESTS ( Continued )
SPEED MODE
Start with the Treadmill turned OFF at the ON/OFF switch.
Power up the unit while holding the INCLINE DOWN ∇KEY.
Press the SPEED UP ∆KEY to start the Striding Belt moving. Notice that the fourth LED from the top will start
flashing. This shows that the Opto Speed Sensor is functioning.
The Display will present two numbers. The left side number represents the actual speed. The right side number
represents the power applied to the Drive Motor. The unit will supply a fixed percentage of power to the Drive
Motor in the speed mode.
HEART RATE MODE
The user must have the Heart Rate Transmitter and Receiver attached in their proper positions for the Heart Rate
to display. By pressing ENTER, the users Heart Rate will appear on the display’s readout.
POWER MODE
Start with the Treadmill turned OFF at the ON/OFF switch.
NOTE: DO NOT STAND ON THE STRIDING BELT DURING POWER UP.
Power up the unit while holding the INCLINE UP ∆KEY.
The Striding Belt will begin to move at .5 mph. Grasp the handlebar and begin walking on the Striding Belt. Walk
forward taking the smallest steps possible. This test will indicate the power draw on the treadmill. The average
amount is 8 to 12 and will vary according to the technicians weight. Excessively high numbers may indicate either
a newer, non-broken-in striding belt or a very old, worn belt.

1
Life Fitness Model 5500HR Treadmill
HOW TO ... REMOVE AND REPLACE THE MOTOR COVER
Tools Required: Phillips screwdriver
Step 1
Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
Step 2
Using a Phillips screwdriver, remove the four SCREWS securing the MOTOR COVER and remove the damaged
MOTOR COVER.
Step 3
Place the new MOTOR COVER in position and replace the four SCREWS.

2
Life Fitness Model 5500HR Treadmill
How To... REMOVE AND REPLACE THE HEATSINK CONTROL BOARD
Tools Required: Phillips screwdriver
WARNING: FAILURE TO OBSERVE SAFETY PROCEDURES WHEN SERVICING
THIS UNIT COULD RESULT IN INJURY FROM ELECTRICAL SHOCK
Step 1
Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
Step 2
Remove MOTOR COVER (See “How To ...”).
Step 3
Ground yourself to the machine by positioning an ANTI-STATIC GROUNDING STRAP around your wrist and
attaching the end to a MOUNTING SCREW, or a connecting GROUND WIRE SCREW.
NOTE: TAKE A MOMENT TO NOTE THE LOCATIONS OF THE CONNECTORS PRIOR TO
UNPLUGGING THEM FROM THE HEATSINK CONTROL BOARD.
Step 4
Unplug the eight CONNECTORS from the
HEATSINK CONTROL BOARD.
Step 5
Remove the red CAPACITOR CAP.
NOTE THE POLARITY OF THE WIRES
ON THE CAPACITOR -
POSITIVE (+) RED, NEGATIVE (-) BLACK
Step 6
Using a Phillips screwdriver, remove the two
SCREWS securing the wires to the top of the
CAPACITOR from the HEATSINK
CONTROL BOARD.
Step 7
Using a Phillips screwdriver, loosen and remove
the two SCREWS securing the HEATSINK
CONTROL BOARD to the MOTOR PAN.
Step 8
Carefully lift the malfunctioning HEATSINK
CONTROL BOARD from the machine and set
aside.
Step 9
Place the new HEATSINK CONTROL BOARD
into position and reverse steps 1through 8 to
return all parts to their proper locations.
Continued