Life Fitness T3 User manual

T-Series Consumer Treadmills
T5i/T7i
T3
T5

Customer Support Services
SERVICE MANUAL

Life Fitness T-Series Consumer Treadmills
INTRODUCTION
HOW TO USE SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Treadmill Models T3/T5 and T3i/T5i/T7i. Note: Information represents typical
configuration and may differ slightly from actual equipment. The Service Manual provides recommendations of safe
and efficient approaches to problem situations. This manual is separated into five sections.
INTRODUCTION
TABLE OF CONTENTS
Section I
GTROUBLESHOOTING GUIDES
Section II
GDIAGNOSTIC MODE
Section III
G"How To..." SERVICE AND REPAIR GUIDES
Section IV
GELECTRONIC OVERVIEW
GWIRING BLOCK DIAGRAMS
Section V
GMISCELLANEOUS INFORMATION
Refer to TABLE OF CONTENTS for section topics.
When an operating problem occurs, refer to troubleshooting guides and diagnostic mode to isolate cause . When
applicable, guides are listed by problem symptom followed with suggestions of probable cause(s) .
Once source of problem is identified, consult "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.
A reproducible FAX order claim form is given in COMMUNICATING BY TELEFACSIMILE for convenient ordering of
service parts.
To order, 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 ( CST).
Via post - At address cited.
To speed Life Fitness Customer Support Services response to your needs, please provide the following information.
1. Model number
2. Serial number
3. Symptom of problem
4. Part name and number to order (if known)
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 West Belmont
Franklin Park, IL 60131-1548
Telephone – 1-800-328-9714, 1-847-451-0036
FAX – 1-800-216-8893

Life Fitness T-Series Consumer Treadmills
TABLE OF CONTENTS
SECTION I TROUBLESHOOTING GUIDE PAGE
NO POWER..........................................................................................................................2
NO INCLINE..........................................................................................................................2
START UP ERROR...............................................................................................................3
RUNNING ERROR................................................................................................................3
BELT MOVING ERROR........................................................................................................3
OVERSPEED ERROR..........................................................................................................3
FET STUCK –ON ERROR....................................................................................................3
RPM NOISE ERROR ............................................................................................................3
M-CHECKSUM ERROR........................................................................................................3
MOTOR CONTROL ERROR................................................................................................3
M-UNKNOWN ERROR.........................................................................................................3
STRIDING BELT IS TRAVELING BEYOND TRACKING LIMITS.........................................3
UNIT RESETS RANDOMLY OR PAUSES...........................................................................4
DISPLAY OVERLAY KEYS ARE NOT RESPONDING WHEN DEPRESSED.....................4
STRIDING BELT SLIPS DURING FOOTFALL.....................................................................5
MAXIMUM SPEED IS REDUCED.........................................................................................5
KNOCKING SOUND COMING FROM DECK.......................................................................5
RUBBING SOUND FROM UNDERNEATH MACHINE.........................................................5
SQUEAKING NOISE.............................................................................................................5
LOUD GROANING SOUND..................................................................................................5
DISPLAY READS CONTINUOUS HEART RATE.................................................................6
NO CHEST STRAP DETECTED ..........................................................................................6
NOTES..................................................................................................................................7
SECTION II DIAGNOSTIC MODES
DISPLAY CONSOLES....................................................................................................................2
DIAGNOSTIC MENU INSTRUCTIONS..........................................................................................3
ACCESSING DIAGNOSTICS.................................................................................................3
HOW TO MOVE AROUND IN DIAGNOSTICS......................................................................3
HOW TO EXIT DIAGNOSTICS..............................................................................................3
USER MENU STATES ...........................................................................................................3
DIAGNOSTIC STATES...................................................................................................................4
1. SOFTWARE VERSION NUMBERS...................................................................................4
2. DISPLAY TEST MODE.......................................................................................................4
3. KEYPAD TEST MODE .......................................................................................................4
4. MOTOR TEST MODE ........................................................................................................6
5. TREADMILL STATISTICS..................................................................................................8
7. PHOTOSHOOT MODE ......................................................................................................9
USER MENU INSTRUCTIONS.......................................................................................................10
ACCESSING THE USERS MENU..........................................................................................10
HOW TO MOVE AROUND IN THE USERS MENU...............................................................10
HOW TO EXIT THE USERS MENU.......................................................................................10
USER MENU STATES ...........................................................................................................10
USER MENU STATES....................................................................................................................11
USER STATISTICS (T3i/T5i ONLY).......................................................................................11
UNIT SETTINGS.....................................................................................................................11
SOFTWARE VERSION NUMBERS.......................................................................................11
NOTES............................................................................................................................................12

Life Fitness T-Series Consumer Treadmills
TABLE OF CONTENTS - Continued
SECTION lll HOW TO…REPLACE
STRIDING BELT AND DECK .........................................................................................................2
ADJUSTING BELT TRACKING......................................................................................................5
ADJUSTING STRIDING BELT TENSION ......................................................................................6
MOTOR DRIVE BELT.....................................................................................................................7
DRIVE MOTOR...............................................................................................................................8
FRONT ROLLER ............................................................................................................................9
REAR ROLLER...............................................................................................................................10
LIFESPRING ABSORBERS ...........................................................................................................11
LIFT MOTOR ..................................................................................................................................12
MOTOR CONTROLLER.................................................................................................................13
LEVELER ASSEMBLY....................................................................................................................14
DISPLAY BOARD PCB...................................................................................................................15
TELEMETRY RECEIVER and HEART RATE CABLE (If Equipped)..............................................16
MAIN WIRE HARNESS ..................................................................................................................17
MEMBRANE SWITCH and MODULE BUTTONS ..........................................................................18
OVERLAY ASSEMBLY...................................................................................................................19
HANDRAIL ASSEMBLY – MODELS T5/T5i/T7i.............................................................................20
NOTES............................................................................................................................................21
SECTION IV ELECTRONICS OVERVIEW AND WIRING DIAGRAMS
T3i/T5i /T7i CONSOLE....................................................................................................................2
T3/T5 CONSOLE............................................................................................................................4
MOTOR CONTROLLER PCB.........................................................................................................6
BLOCK DIAGRAM ..........................................................................................................................8
NOTES............................................................................................................................................9
SECTION V MISCELLANEOUS INFORMATION
PREVENTIVE MAINTENANCE......................................................................................................2
UNPACKAGING INSTRUCTIONS .................................................................................................3
INSTALLATION INSTRUCTIONS ..................................................................................................4
COMMUNICATING BY FAX...........................................................................................................10
LIFE FAX.........................................................................................................................................11
NOTES............................................................................................................................................12

©1998 Brunswick Corporation. All rights reserved. Life Fitness is a registered trademark of Brunswick Corporation.
Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation. Any use of these trademarks, without the express
written consent of Brunswick Corporation, is forbidden.
U.S. Patent Numbers 3,767,195 and 4,358,105.
6841601
03-2000

Section 1 1
Life Fitness T-Series Consumer Treadmills
TROUBLESHOOTING GUIDE
SECTION I
TROUBLESHOOTING GUIDE
Section I

Section 12
Life Fitness T-Series Consumer Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
On/Off switch. Turn the switch to the ON position.
Insufficient power source. Plug treadmill into a dedicated circuit.
Using a voltmeter, verify power at outlet.
Verify/Reset 15 amp circuit breaker.
Verify line voltage at P5 on motor controller
pins 1 and 2.
If yes, verify 8 VDC at P1 pins 7 and 8, and
8VDC at P1 pin 6.
If voltage is present, verify continuity and
voltage at the console end of the main cable, If
8VDC is present, replace display console PCB.
If 8 VDC at P1 pins 7 and 8, and 8VDC at P1
pin 6 of the motor controller is not present,
replace motor controller.
Damaged line cord. Replace line cord.
No Power.
Line cord improperly seated in
socket. Inspect power connection at wall outlet and at machine for proper contact.
No incline. Home switch disconnected or
damaged. Test in Diagnostics. See Motor Test Mode in Section 2.
Verify key pad function in diagnostics.
Test lift motor function in diagnostics.
Verify P4 Connector, Pin 2 has AC voltage.
Verify P4 Connector, Pins 1 and 2 have line
current when declining.
Verify P4 Connector, Pins 1 and 3 have line
current when inclining. If voltages are present,
replace lift motor.

Section 1 3
Life Fitness T-Series Consumer Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Display reads:
Start up error/Err1 Belt was commanded to move
and the opto has not seen any
movement or the belts
movement was interrupted
prior to it reaching its
commanded speed
Verify opto operation in Diagnostics, Motor Test
Mode, Section 2. Verify DC voltage at
connector P6 pins 1 and 2. Verify that LED 4 on
the Motor Controller flashes as the motor
moves.
Display reads:
Running error/Err2 Belts movement was
interrupted or lost opto after
reaching its commanded
speed.
Check opto connections. Verify opto operations
in Diagnostics, Motor Test Mode, Section 2,
and that LED4 flashes as motor moves.
Display reads:
Belt Moving error/Err3 Belt movement detected prior
to receiving a command. Make sure user is not pushing belt manually. If unit is moving without command, replace the
motor controller.
Display reads:
Overspeed Error/Err4 Belt movement is exceeding
command by 3 Mph. Verify opto operation in Diagnostics, Motor Test Mode, Section 2. Replace motor controller if
actual speed exceeds target speed.
Display reads:
FET Stuck On Error/Err5
Driver transistor on the motor
controller is detected to be
shorted.
Replace The motor controller
Display reads:
Rpm Noise Error/Err6 RPM sensor (opto) is erratic
(this error is only seen in Motor
Test Mode).
Verify opto operation in Diagnotics, Motor Test
Mode, Section 2. Replace opto sensor if
necessary.
Display reads:
M- Checksum error/Err7
Or Motor Comm Error/Err0
Console lost communication
with motor controller. Check connection and continuity on main harness using mutimeter. Replace opto sensor
if necessary.
Display reads:
M-Unknown Error/Err9 Multiple errors 9-255, only seen
on motor test mode. Exit Diagnotics to view error message and trobleshoot accordingly.
Striding belt needs to be re-
tensioned or tracking needs
adjustment.
Refer to belt tensioning or tracking adjustment
procedure in operation or service manual.
The Striding Belt is
traveling beyond the
tracking limits.
Worn striding belt or user
pushing belt. Center striding belt according to belt centering technique. See How To...Adjust And Tension
The Striding Belt.
Section I

Section 14
Life Fitness T-Series Consumer Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Insufficient power source. Plug treadmill into a dedicated circuit.
Line cord improperly seated in
electrical outlet. Inspect power connection at electrical outlet and at machine for proper contact.
Emergency stop magnet not
engaged. Re-engage the emergency stop magnet.
Loose or damaged
telecommunication
connections at display console
or motor controller.
Disconnect and reconnect telcom and motor
controller. Replace telcom if necessary.
Unit resets randomly or
pauses.
Open ground path. Using multimeter, check all points for
continuity: console pan screws, console
mounting screws, handlebar screws, and
handrail mounting screws to frame with respect
to ground. Ground must be a non-painted
surface.
Loose ribbon connection(s). Test keypad in Diagnostics. See Section 2.
Verify that ribbon connections are attached to
the display PCB.
Reseat the connection and verify the operation.
Worn or defective overlay
assembly. Replace overlay assembly. See How To… Replace Overlay Assembly. See operation in
Diagnostic. See Section 2.
Display overlay keys are
not responding when
depressed.
Secondary key pad T3i/T5i/T7I
not responding Test the keypad in Diagnostics. See Section 2. 1. Inspect ribbon cable connection.
2. Remove and inspect that button tabs on
module assembly are making contact with
membrane switch. If not, replace module. If
contact is being made with membrane and key
pad is still not responding, replace the
membrane.

Section 1 5
Life Fitness T-Series Consumer Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Striding Belt slips during
footfall. Striding belt slips on front roller
during stall test. Check striding belt & re-tension as necessary. See How…To Adjust Belt Tension.
User is pushing striding belt. Instruct users not to push striding belt in either
direction.
Striding belt/deck malfunction.
The deck laminate worn
through or the underside of
striding belt glazed over (hard,
glossy).
Test in Diagnostics. If amp draw exceeds 13
amps replace belt and deck. See How
To…Replace Striding Belt.
Maximum speed is
reduced.
Insufficient power source. Plug treadmill into a dedicated circuit.
Faulty rear roller bearings. Replace rear roller assembly.
Knocking sound at rear of
machine.
Wax build up on rear roller. Run unit for 10 hours to break-in the treadmill.
Knocking sound coming
from deck. Life Springs not positioned
correctly and/or loose mounting
hardware.
Reposition or tighten life springs.
Rubbing sound from
underneath machine. Foreign objects may be stuck
underneath the machine. Inspect underneath striding belt and machine. Remove any debris or objects that may cause
interference with the treadmill.
Squeaking noise. Drive motor belt may be worn
or misalined. Replace drive motor belt. See How To… Replace Drive Motor Belt.
Extrusions may be slipping on
metal extrusion clips. Replace metal clips with plastic clips.
Lift mechanism pivot points or
lift screw are dry. Lubricate pivot points or lift screw with grease.
Loud groaning sound
heard from front of
machine while elevating.
Faulty lift motor. Replace the lift motor. See How To…Replace
Lift Motor.
Loud groaning on footfall. High friction between deck and
striding belt. Test in Diagnostics. If amp draw exceeds 13 amps while running on machine, replace belt
and deck. See How To…Replace Striding Belt.
Section I

Section 16
Life Fitness T-Series Consumer Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Display reads a continuous
heart rate. RF Interference. Move location of machine.
Chest strap sensors not making
good contact with body of user. Adjust chest strap and moisten sensors to make better contact with skin.
User is out of monitoring range. Move within 3 ft (1 meter) of receiver
Loose connection at receiver. Check connection on receiver.
Faulty chest strap. Replace chest strap.
No Chest Strap detected (if
equipped).
Faulty receiver. Verify 5VDC at P3 pin 1. If yes, replace
transmitter. If no, replace display console
PCB.

Section 1 7
Life Fitness T-Series Consumer Treadmills
NOTES:
Section I

Section 2 1
Life Fitness T-Series Consumer Treadmills
SECTION II
DIAGNOSTICS
Section II

Section 22
Life Fitness T-Series Consumer Treadmills
DISPLAY CONSOLES
T3/T5
T3i/T5i/T7i

Section 2 3
Life Fitness T-Series Consumer Treadmills
DIAGNOSTICS MENU INSTRUCTIONS
ACCESSING DIAGNOSTICS
Press the Stop button twice in a row and then hold down the Quick Start-Walk button or
alternatively hold down the Quick Start-Walk button and turn the treadmill ON. The console will
automatically jump into the 1st diagnostic state. TheT3/5 console the Time LED will be lit to
indicate that you are in the 1st state.
HOW TO MOVE AROUND IN DIAGNOSTICS
Use the ENTER button to move forward through the diagnostics states as listed below. Use the
STOP button to move backwards.
HOW TO EXIT DIAGNOSTICS
There are two ways to exit diagnostics. You can just turn OFF the treadmill (all setting will be
saved). Or you can keep pressing the STOP button to move all the way back to the beginning of
diagnostics and then out of diagnostics.
USER MENU STATES
The diagnostic states are as follows:
•1. Software Version Numbers
•2. Display Test Mode
•3. Keypad Test Mode
•4. Motor Test Mode
•5. Treadmill Statistics
•6. Photoshoot Mode
Section II

Section 24
Life Fitness T-Series Consumer Treadmills
DIAGNOSTIC STATES
1. SOFTWARE VERSION NUMBERS
This state shows the current Software Version for the Console, Motor Controller, and Software Part Number. Use
the up/down arrow keys for the T3i/T5i and T7i Consoles. Use the time arrow keys on T3/T5 Consoles. Use these
keys to toggle between the console software version and the motor controller version. The Console software
version number is displayed as “CONSOLE VER=PXX.X” on the T3i/T5i and CONxx.x is the version number on
the T3/5. The motor controller software version number is displayed “MOTOR VER=PXX.X” on the T3i/T5i/T7i and
Pxx.x is the version number on the T3/5.
This state checks the Polar receiver. The Heart Rate LED blinks at the same rate as the receiver Heart Rate. If the
LED never blinks then the Console is not receiving a polar sign.
2. DISPLAY TEST MODE
This state scrolls the LEDs. The Time Window consists of four(4) segments. During this operation, the first and last
segments will not display decimals
3. KEYPAD TEST MODE
This state allows you to test the keypad. Anytime you press a key, you will hear a beep, and will see what key you
have pressed in the display.
Keypad Test Table T3i/T5i/T7i
Button Display
Workout Profiles WPPPPPPPPPPPPPPP
Up Arrow ^^^^^^^^^^^^^^^^^^
Down Arrow vvvvvvvvvvvvvvvvvvvvvv
My Workout UUUUUUUUUUUUUUUUUU
Time Up T-^^^^^^^^^^^^^^^^
Time Down T-vvvvvvvvvvvvvvvvvvv
Walk WWWWWWWWWWW
Jog JJJJJJJJJJJJJJJJJJJJJJJJJJJ
Run RRRRRRRRRRRRRRR
Enter This will automatically jump to the next diagnostics state
Cool Down CCCCCCCCCCCCCCC
Incline Up I-^^^^^^^^^^^^^^^^^
Incline Down I-vvvvvvvvvvvvvvvvvv
Stop This will automatically jump to the last diagnostics state
Speed Up S-^^^^^^^^^^^^^^^^^
Speed Down S-vvvvvvvvvvvvvvvvvv
When pulled "E STOP--------"Emergency Stop
Switch When replaced "---------------"

Section 2 5
Life Fitness T-Series Consumer Treadmills
DIAGNOSTIC STATES - Continued
3. KEYPAD TEST MODE - Continued
This state allows you to test the keypad. Anytime you press a key, you will hear a beep, and will see what key you
have pressed in the display.
Keypad Test Table -T3/T5
Button Display
Workout Profiles "AAAA AAA AAA" - (no LED's will be lit)
Enter This will automatically jump to the next diagnostics state
Time Up "uuuu uuu uuu" - (Time LED will light)
Time Down "dddd ddd ddd" - (Time LED will light)
Cool Down "CCCC CCC CCC" - (no LED's will be lit)
Incline Up "uuuu uuu uuu" - (Incline LED will light)
Incline Down "dddd ddd ddd" - (Incline LED will light)
Stop This will automatically jump to the last diagnostics state
Speed Up "uuuu uuu uuu" - (Speed LED will light)
Speed Down "dddd ddd ddd" - (Speed LED will light)
Start "SSSS SSS SSS" - (no LED's will be lit)
Walk "bbbb bbb bbb" - (no LED's will be lit)
Jog "cccc ccc ccc" - (no LED's will be lit)
Run "dddd ddd ddd" - (no LED's will be lit)
When pulled "EEEEEEEEEE"Emergency Stop
Switch When replaced "---------------"
Section II

Section 26
Life Fitness T-Series Consumer Treadmills
DIAGNOSTIC STATES
4. MOTOR TEST MODE - Models T3/T5 only
This state allows you to test the drive and Incline Motor and get motor controller power usage. The motor can
be stopped immediately by pulling the Emergency Stop switch or by pressing the Stop button.
To test the drive motor use the speed arrow keys to command the motor from 0 MPH to the maximum speed
set for the units (10 MPH T3/T3i and 12 MPH T5/T5i/T7i). If the unit is configured to 12 MPH the speed LED will
be ON and OFF if its configured to 10 MPH.
To test the lift motor use Incline Up/Down Keys to drive lift motor. Once either arrow key is selected the lift
motor will run non-stop until reaches internal limit switch. This action can be stopped by pressing the arrow key
a second time. The Incline LED will be OFF when the unit home switch is activated (0% elevation).
Console T3/T5 - The Speed Window shows the command set speed, the Incline Window shows the target
speed (OPTO Sensor), and the Time Window shows the power usage.
The Cool Down key allows error messages to be reset.
XXXX XX.X XX.X
Time Incline Speed
Enter
Workout
Profiles
Cool
Down Stop Start Run
Jog
Walk
Critical Motor
Errors
RPM Noise
Errors
Packet
Checksum
Errors
Press to
clear motor
errors
Motor Controller
Power Value and
Motor error numbers
Incline motor
going up
Incline motor
going down
Incline motor
stopped or ESTOP
replaced
P
E
= Power
= ESTOP pulled
Motor
Comm
errors
Incline Motor
errors
OPTO
speed
Max Speed
setting
Target
Speed

Section 2 7
Life Fitness T-Series Consumer Treadmills
DIAGNOSTIC STATES
4. MOTOR TEST MODE - Models T3i, T5i, T7i only
This state allows you to test the drive and Incline Motor and get motor controller power usage. The motors can
be stopped immediately by pulling the Emergency Stop switch or by pressing the Stop button.
To test the drive motor use the speed arrow keys to command the motor from 0 MPH to the maximum speed
set for the units (10 MPH T3/T3i and 12 MPH T5/T5i/T7i). If the unit is configured to 12 MPH the speed LED will
be ON and OFF if its configured to 10 MPH.
To test the lift motor use Incline Up/Down Keys to drive lift motor. Once either arrow key is selected the lift
motor will run non-stop until reaches internal limit switch. This action can be stopped by pressing the arrow key
a second time. The Incline LED will be OFF when the unit home switch is activated (0% elevation).
Console T3i/T5i/T7i - The Speed/HR window shows the command set speed, the Incline/Distance window
shows the target speed (OPTO Sensor), and the Calories/Hours window shows the power usage.
The Cool Down key allows error messages to be reset.
XXX
Incline Speed
Distance Heart Rate
Calories / Hour
Time in Zone
Calories
Walk
Jog
Run
Time
Cool
Down
Enter
My
Workout
Workout
Profiles
RPM noise errors
Incline
Home
Switch
Max Speed
Setting
Critical Motor
errors Packet
Checksum
errors
Motor-Comm
errors
Press to clear
motor errors
XXX XXX
XXX
Motor
error
number
Motor Controller
Power Value
Target
Speed
OPTO
Sensor
E Stop Indicator:
E=switch pulled
=switch attached
Section II