Life Fitness Lifecycle 3500 Series, Service Manual

Page 1: ...Lifecycle 3500 4500 5500 Series Exercise Bikes Customer Support Services SERVICE MANUAL ...

Page 2: ... 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 If you do not have a part in stock a form to order by FAX has been included in Section V for your convenience or you can call Life Fitnes...

Page 3: ...emark Office Certificate No 1 400 502 issued July 8 1986 Lifecycle Lifepulse 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 00K17 A079 6 97 ...

Page 4: ... 10 Too Easy To Pedal 11 Tension Stays The Same 12 Will Not Pedal Forward 13 Flashing Prompt Goes Off When Start Button Is Released 14 SECTION II DIAGNOSTICS Lifecycle 3500 4500 5500 Series Exercise Bikes 1 3 SECTION III How To REMOVE AND REPLACE THE Alternator 1 Alternator Control Board 2 Alternator Belt 3 Battery 4 Chain 5 Crank Bearing Nut Assemblies 6 7 Footstraps 8 Handlebar Assembly Display ...

Page 5: ...ontrol Board Defective Alternator q Pedal at 80 RPMs q Massage keypad with fingertips q Test battery voltage or replace with fully charged 9V alkaline battery q Check wire harness for loose connections at Display Console Alternator Control Board Alternator and Battery q Check wire harnesses for damage q Switch or replace Display Console q Switch or replace Alternator Control Board q Switch or repl...

Page 6: ... on Loose connection or damaged harness Defective Display Console Defective Alternator Control Board Defective Alternator q Reseat Connectors at Display Console Alternator Control Board Alternator and Battery q Check wire harnesses for damage q Switch Display Console q Switch Alternator Control Board q Switch Alternator For Assistance Call Life Fitness Customer Support Services 1 847 451 0036 or 1...

Page 7: ...e Loose wire connections Damaged wire harness Defective Alternator Control Board Defective Aternator q Pedal at 80 RPMs q Check battery voltage or replace with a fully charged 9V alkaline battery q Reseat connector at Display Console Alternator Control Board Alternator and Battery q Check wire harness for damage q Switch or replace Alternator Control Board q Switch or replace Alternator For Assist...

Page 8: ...Action Flashing prompt remains ON Not Pedaling Fast Enough Not entering acceptable data Defective Display Console Defective Alternator Control Board q Pedal at 80 RPMs q See Operation Manual q Switch Display Consoles q Switch Alternator Control Board For Assistance Call Life Fitness Customer Support Services 1 847 451 0036 or 1 800 351 3737 ...

Page 9: ...ess Alternator output low Defective Display Console Defective Alternator Control Board Defective Alternator q Pedal at 80 RPMs q Reseat connector at Display Console Alternator Control Board Alternator and Battery q Check wire harness for damage q Check Alternator Output q Switch Display Consoles q Switch Alternator Control Board q Switch Alternator For Assistance Call Life Fitness Customer Support...

Page 10: ...ve Alternator Control Board Alternator output low Defective Alternator q Pedal at 80 RPMs q Reseat connector at display console Alternator Control Board Alternator and Battery q Check wire harness for damage q Switch Display Consoles q Switch Alternator Control Board q Check Alternator output Should be 9 10V Red probe on output Black probe on ground Pedal and press Start q Switch Alternator For As...

Page 11: ...ive Action Keys do not respond Entering unavailable programs May be in cold area Defective Display Console Overlay Defective Display q See Operation Manual q Massage keypad with fingertips to warm q See diagnostics on keypad test q Switch or replace Display Console For Assistance Call Life Fitness Customer Support Services 1 847 451 0036 or 1 800 351 3737 ...

Page 12: ...against housing Damaged crank bearings Loose or damaged chain Alternator flywheel assembly damaged or worn Worn freewheel Gear q Adjust seat height q Adjust or replace crank bearings q Tighten the drive belt It should have 1 4 6mm maximum play q Replace worn drive belt q Tighten crank nut q Replace worn crank bearings q Replace chain q Replace Alternator flywheel assembly q Replace freewheel gear ...

Page 13: ...le Defective Alternator Control Board Alternator output low Defective Alternator q Pedal at 80 RPMs q Reseat connector at display console Alternator Control Board Alternator and Battery q Check wire harness for damage q Replace overlay bezel q Switch Display Consoles q Switch Alternator Control Board q Check Alternator output Should be 9 10V Red probe on output Black probe on ground Pedal and pres...

Page 14: ...y is off Left crank nut too tight Drive belt too tight Defective freewheel gear Defective crank bearings q Loosen left crank nut 1 16 turn q Loosen drive belt tension There should be 1 4 6mm maximum play q If user can not pedal backwards replace the freewheel gear q Replace crank bearings For Assistance Call Life Fitness Customer Support Services 1 847 451 0036 or 1 800 351 3737 ...

Page 15: ...d Alternator has incorrect voltage output Defective Alternator q Choose higher workout level q Pedal at 80 RPMs q Tighten drive belt q Replace chain q Reseat connector at display console Alternator Control Board Alternator and Battery q Check wire harness for damage q Switch Display Consoles q Switch Alternator Control Board q Check Alternator output Should be 9 10V Red probe on output Black probe...

Page 16: ...rol Board Alternator has incorrect voltage output Defective Alternator q Choose higher workout level q Pedal at 80 RPMs q Tighten drive belt q Replace chain q Reseat connector at display console Alternator Control Board Alternator and Battery q Check wire harness for damage q Switch Display Consoles q Switch Alternator Control Board q Check Alternator output Should be 9 10V Red probe on output Bla...

Page 17: ...Chain has frozen link s Left crank nut too tight Crank bearings worn or rusted q Freewheel gear should rotate backward freely if not replace It q Loosen drive belt Belt should have a 1 4 6mm maximum play q Replace chain q Loosen crank nut by 1 16 turn q Replace crank bearings For Assistance Call Life Fitness Customer Support Services 1 847 451 0036 or 1 800 351 3737 Lifecycle 3500 4500 5500 Series...

Page 18: ... Control Board Alternator has incorrect voltage output Defective Alternator q Choose higher workout level q Pedal at 80 RPMs q Tighten drive belt q Replace chain q Reseat connectors at Display Console Alternator Control Board Alternator and Battery q Check wire harness for damage q Switch Display Consoles q Switch Alternator Control Board q Check Alternator output Should be 9 10V Red probe on outp...

Page 19: ...15 Lifecyle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 20: ...16 Lifecyle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 21: ...ART while pedaling the bike over 55 RPM On entry all LED s and 7 segment displays will be on You are now in Diagnostics State 1 In ALL DIAGNOSTICS STATES the user must keep pedaling the bike If the pedal RPM drops too low the bike will shut down requiring at least 30 RPM or greater and a START switch closure to operate again Continued ...

Page 22: ...s State 2 DIAGNOSTICS STATE 2 This test indicates that all LED s on the Display are working properly Upon entry the system will beep twice and begin walking through a sequence of LED s as follows The decimal points in the top 7 segment display the FASTER SLOWER LEVEL and MILES or KM LED s the decimal points in the bottom 7 segment display the CAL HR or WATTS TOTAL CAL HILL RANDOM and MANUAL LED s ...

Page 23: ... is indicated by an A Left center digit q ENGLISH units of measurement are indicated by an E q METRIC units of measurement are indicated by a G Right center digit q RECUMBENT is indicated by an r q UPRIGHT is indicated by a U For example A E U represents NON RECHARGEABLE ENGLISH UPRIGHT The MULTI FUNCTION DISPLAY WINDOW will display information regarding the software A P to represent PRODUCTION fo...

Page 24: ...4 Lifecycle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 25: ...TMENT BOLT Step 4 With two 3 4 wrenches loosen the PIVOT BOLT and LOCKNUT located on the ALTERNATOR DO NOT REMOVE THE PIVOT BOLT AND LOCKNUT UNTIL STEP 7 Step 5 Cup your hand under the worn ALTERNATOR and lift upward This will relieve the tension from the ALTERNATOR BELT Step 6 With your other hand slide the ALTERNATOR BELT off the large FREE WHEEL PULLEY Loop the ALTERNATOR BELT around the FLYWHE...

Page 26: ...POSTS on the ALTERNATOR With a 1 4 wrench remove the two NUTS securing the BLACK FIELD WIRE and the WHITE WIRE With a 5 16 wrench remove the REGULATOR TERMINAL NUT and the GROUND TERMINAL NUT Step 6 With a 3 8 wrench remove the RESISTOR NUT and WASHER that secure the RESISTOR to the ALTERNATOR BRACKET Step 7 Use pliers to carefully collapse the top of the four STANDOFFS which secure the worn ALTER...

Page 27: ...OCKNUT located on the ALTERNATOR Step 4 Cup your hand under the worn ALTERNATOR and lift upward This will relieve the tension from the ALTERNATOR BELT Step 5 With your other hand slide the ALTERNATOR BELT off the large FREE WHEEL PULLEY Loop the ALTERNATOR BELT around the FLYWHEEL located at the end of the ALTERNATOR SHAFT to remove Step 6 Reverse steps 1 through 5 to return all parts back into th...

Page 28: ...IRES out so that you can disconnect the worn BATTERY Connect the NEW BATTERY in it s place WARNING ONLY USE AN ALKALINE TYPE BATTERY USE OF ANY OTHER TYPE BATTERY MAY RESULT IN A MALFUNCTION OR DAMAGE Step 3 Carefully tuck the BATTERY WIRES back into the DISPLAY CONSOLE and set the new BATTERY into position Reinstall the BATTERY DOOR by inserting the TABS at the bottom of the DOOR into the opening...

Page 29: ... pliers remove the MASTER LINK RETAINING CLIP the MASTER LINK and the MASTER LINK PLATE from the worn CHAIN Step 3 Install the new CHAIN around the CRANK and FREEWHEEL GEAR Step 4 Insert the new MASTER LINK through the ends of the new CHAIN and snap the new MASTER LINK PLATE over the new MASTER LINK Then with a needle nose pliers install the new RETAINER CLIP onto the new MASTER LINK with the ends...

Page 30: ...ame Discard the two BEARING CLAMP BOLTS two SPLIT LOCKWASHERS and the four BEARING CLAMPS as they are not to be re used Step 5 Figure 2 Bend the outward tab of the TAB LOCK WASHER to allow rotation of the REVERSE THREADED LOCK NUT Using the 32mm crank arm wrench loosen and remove the REVERSE THREADED LOCK NUT Remember this NUT is REVERSE THREADED NOTE NUTS ON THE LEFT SIDE ARE REVERSE THREADED i e...

Page 31: ... bent tab facing toward the bike FRAME Slide the key of the TAB LOCK WASHER through the notch and into position against the CRANK BEARING NUT ASSEMBLY Align the flat of the bent TAB against the flat of the NUT as shown in the diagram Step 15 Slide the REVERSE THREADED LOCK NUT over the CRANK ARM thread it into position and with the 32mm crank arm wrench tighten the REVERSE THREADED LOCK NUT to 4 F...

Page 32: ... worn STRAP and pull AWAY and DOWN from the knob on the PEDAL Step 3 Insert the outside of the new STRAP slit on to the outside knob of the PEDAL Pull the STRAP UP to a click locking it in place Step 4 Insert the inside of the new STRAP on to the inside knob of the PEDAL Pull the STRAP UP to a click locking it in place NOTE THE STRAP HAS THE INITIAL L FOR LEFT AND R FOR RIGHT MOLDED IN THE CORNER ...

Page 33: ...DLEBAR ASSEMBLY from the bike Step 3 With an 1 8 hex key wrench loosen and remove the three DISPLAY CONSOLE SCREWS securing it to the HANDLEBAR ASSEMBLY Step 4 Carefully guide the 8 PIN CONNECTOR of the wire harness into the base of the HANDLEBAR POST Lift the DISPLAY CONSOLE slowly to avoid damage to the wire harness as you pull it out of the top of the HANDLEBAR ASSEMBLY Step 8 Replace the DISPL...

Page 34: ... DISPLAY CONSOLE SCREW located within the tubular frame of the DISPLAY CONSOLE BRACKET Step 6 With a 1 8 hex key wrench loosen and remove the two DISPLAY CONSOLE SCREWS from the underside of the DISPLAY CONSOLE Step 7 Carefully guide the 8 PIN CONNECTOR of the wire harness into the slot at the base of the HANDLEBAR POST Lift the DISPLAY CONSOLE slowly to avoid damage to the wire harness as you pul...

Page 35: ...te the FREE WHEEL GEAR in a counter clockwise direction WARNING BE EXTREMELY CAREFUL NOT TO OVER FORCE AND DAMAGE THE ALUMINUM THREADS OF THE FREE WHEEL GEAR DURING THIS PROCEDURE Step 4 Remove the E Ring on the FREEWHEEL SHAFT and carefully push the SHAFT and the FREEWHEEL through the Brass Bearings and out the user left side of the Bike Step 5 Replace with a new FREE WHEEL GEAR When you position...

Page 36: ...G remove the seven Phillips SCREWS A From the left side of the HOUSING remove the single Phillips SCREW B located at the HANDLEBAR ASSEMBLY Step 4 Swing the CRANK ARM to a two o clock position and slip a PLASTIC TUBE over it to protect the finish of the HOUSING from any possible scuffs or scratches Guide the right side HOUSING up and over the CRANK ARM to remove it from the unit Step 5 Follow the ...

Page 37: ... and remove the PEDAL Step 2 To remove the RIGHT PEDAL sprocket side place a 5 8 open end wrench on the PEDAL BOLT Turn the wrench counter clockwise and remove the PEDAL Step 3 Guide the new PEDALS on the CRANK ARMS To tighten the PEDALS place a 5 8 open end wrench on to the PEDAL BOLT Turn the wrench counter clockwise for the LEFT PEDAL and clockwise for the RIGHT PEDAL Tighten parts to the follo...

Page 38: ...from the worn SEAT POST using a 9 16 wrench Step 3 Reverse Steps 1 and 2 to replace either the SEAT or the SEATPOST NOTE CHECK TO ENSURE THAT THE SIDE PLATE AND CLAMP LOCKING SERATIONS ARE PROPERLY ALIGNED BEFORE FIANL TORQUING OF BOLT Tighten parts to the following specifications Seat Bolt 28 30 ft lbs Step 4 Slide the SEAT POST into the bike frame Adjust the SEAT POST to the desired height and i...

Page 39: ...BILIZER TUBE end Use a RUBBER MALLET to tap it in place Step 4 After placing the Lifecycle Exercise Bikes in the intended location for use check the stability of the bike If the bike is not level turn the FOOT CAP in either direction until the rocking motion is diminished If one end of the Lifecycle is not touching the floor rotate the FOOT CAP so that the large end is touching the surface If one ...

Page 40: ...16 Lifecycle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 41: ...17 Lifecycle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 42: ...044 0000 23 AXLE WHEEL OK17 01110 0000 OK17 01110 0000 24 WHEEL OK17 01111 0000 OK17 01111 0001 25 OFFSET FOOT CAP OK17 01115 0000 OK17 01115 0001 26 CAP FRONT OK17 01148 0000 OK17 01148 0001 27 PULLEY W SHAFT MOLDED OK17 01175 0000 OK17 01175 0000 28 SPROCKET 60 TOOTH OK17 01186 0000 OK17 01186 0000 29 PIN SEAT W MOLDED KNOB OK17 01208 0000 OK17 01208 0000 30 LOCKNUT CRANK LT OK18 01059 0001 OK18...

Page 43: ...2 Lifecycle 3500 4500 5500 Series Exercise Bikes PARTS IDENTIFICATION ...

Page 44: ...3 Lifecycle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 45: ...1 Lifecycle 3500 4500 5500 Series Exercise Bikes MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION ...

Page 46: ...life of the CRANK BEARINGS check for proper tightness of the CRANK NUT bi annually Also watch for wear of the CRANK NUT itself at the point where it meets the BEARING Clean and lubricate the CHAIN with a light motor oil Preventive Maintenance Schedule DAILY BI ANNUALLY ANNUALLY Housing Inside C Outside C Alternator Control C Heatsink C Connectors I I Board I Chain C L Crank Bearings I Pedals C I F...

Page 47: ...3 Lifecycle 3500 4500 5500 Series Exercise Bikes PREVENTIVE MAINTENANCE Continued ...

Page 48: ...4 Lifecycle 3500 4500 5500 Series Exercise Bikes WIRING BLOCK DIAGRAM ...

Page 49: ...a problem we have included for your convenience a FAX form on the following page Simply make a copy or copies of the FAX sheet and fill in the necessary information You may FAX us at any time 24 hours a day to either of the numbers shown A Life Fitness service representative will process your order or respond to your problem as quickly as possible ...

Page 50: ...NO DATE PHONE FAX CONTACT NAME METHOD OF SHIPMENT 1 DAY 2 DAY GROUND PARTS ORDER FORM ITEM NO PART NUMBER DESCRIPTION QUANTITY 1 2 3 4 5 6 PRODUCT TROUBLESHOOTING PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM TIME RECEIVED TIME COMPLETED TECHNICIAN NAME ...

Page 51: ...7 Lifecycle 3500 4500 5500 Series Exercise Bikes NOTES ...

Page 52: ...8 Lifecycle 3500 4500 5500 Series Exercise Bikes NOTES ...