Life Fitness T3, Service Manual

Page 1: ...T Series Consumer Treadmills T5i T7i T3 T5 ...

Page 2: ...Customer Support Services SERVICE MANUAL ...

Page 3: ...le 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 conta...

Page 4: ...ING 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 ...

Page 5: ...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 M...

Page 6: ... 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 ...

Page 7: ...Section 1 1 Life Fitness T Series Consumer Treadmills TROUBLESHOOTING GUIDE SECTION I TROUBLESHOOTING GUIDE Section I ...

Page 8: ...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 ...

Page 9: ... 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 Diagnotic...

Page 10: ... 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 R...

Page 11: ...urs 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 m...

Page 12: ...rs 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 ...

Page 13: ...Section 1 7 Life Fitness T Series Consumer Treadmills NOTES Section I ...

Page 14: ...Section 2 1 Life Fitness T Series Consumer Treadmills SECTION II DIAGNOSTICS Section II ...

Page 15: ...Section 2 2 Life Fitness T Series Consumer Treadmills DISPLAY CONSOLES T3 T5 T3i T5i T7i ...

Page 16: ...he 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...

Page 17: ...rt 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 di...

Page 18: ...ate 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 n...

Page 19: ...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 all...

Page 20: ...e 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 ...

Page 21: ...ed up to 9999 Fat Burns xxxx Number of times this program was selected up to 9999 Cardios xxxx Number of times this program was selected up to 9999 Hill prgs xxxx Number of times this program was selected up to 9999 Randoms xxxx Number of times this program was selected up to 9999 Manuals xxxx Number of times this program was selected up to 9999 EZ Inclin xxxx Number of times this program was sele...

Page 22: ...this program was selected up to 9999 My Workouts xxxx Number of times this program was selected up to 9999 Treadmill Statistics T3 T5 Display Item Data Item xx xx 000 Total accumulated workout time displayed in hours minutes format up to 99 59 99 hours 59 minutes At over 100 hours format changes to xxxx xx000 9999 59 up to 9999 hours and 59 minutes xx xx 001 Total accumulated lift time same format...

Page 23: ... AROUND IN THE USERS MENU Use the Enter button to move forward through the User Menu States listed above Use the Stop button to move backwards Once you are in the last state you must move backwards to get to the other states HOW TO EXIT THE USERS MENU There are two ways to exit the User Menu You can just turn off the treadmill all setting will be saved Or you can keep pressing the Stop button to m...

Page 24: ...the Up Down arrow keys Use the Time Arrows to adjust the settings Unit Settings T3i T5i T7i Display Item Setting Notes Pause Time xx This item sets the maximum time that pause will last It ranges from 1 to 99 minutes Sleep Time xx This item sets the time it takes before Sleep Mode is entered Its ranges if from 1 to 99 minutes or OFF Units English Metric This item sets what units the weight speed a...

Page 25: ...Section 2 12 Life Fitness T Series Consumer Treadmills NOTES ...

Page 26: ...Section 3 1 Life Fitness T Series Consumer Treadmills SECTION III HOW TO SERVICE AND REPAIR GUIDE Section III ...

Page 27: ... each end cap 4 Remove the mounting screw at the front of the left and one at right front extrusion Slide each extrusion back off the extrusion mounting brackets 8 5 Remove extrusion brackets 8 and screws 16 from the deck and set aside to be remounted on the new deck NOTE Before removing the rear roller scribe an L left and an R right on the ends of the roller shaft This will ensure that the rolle...

Page 28: ...ront roller mounting brackets then lift the front roller out from the striding belt If necessary remove the motor drive belt 10 Remove the deck screws 4 and lift out the deck 11 Remove the striding belt and discard 12 Install new striding belt and deck in reverse order Make sure to reinstall extrusion brackets on the new deck Retension the motor drive belt to no more than 1 4 deflection Do not ove...

Page 29: ...EAR ROLLERS Tighten the BELT TENSIONING BOLTS up to the location marks made prior to removal or if not marked until the center span of the belt is taut between rollers 2 After installing new STRIDING BELT but prior to tensioning place two pieces of tape 50 inches apart on BOTH the right and left edges of the STRIDING BELT 50 3 Alternately tighten the two tensioning bolts 1 4 turn clockwise each un...

Page 30: ...ise to start the STRIDING BELT tracking back to the center of the REAR ROLLER If the STRIDING BELT has moved to the left turn the left TENSION BOLT 1 4 turn clockwise and the right TENSION BOLT 1 4 turn counterclockwise to start the STRIDING BELT tracking back to the center of the REAR ROLLER 4 Repeat this adjustment until the striding belt appears centered The belt should be equal distance B on b...

Page 31: ...the BELT 3 Using the speed decrease button bring the STRIDING BELT speed down to 2 mph 3 2 kph With the STRIDING BELT speed at 2 mph 3 2 kph begin walking on the treadmill Tightly grasp the HANDRAILS and attempt to stall the STRIDING BELT If the STRIDING BELT slips continue to Step 4 if it does not slip the tension is correct 4 4 4 4 Stop the treadmill and alternately turn the STRIDING BELT TENSIO...

Page 32: ... plate in the slotted holes towards the rear roller to relieve belt tension 5 Remove the motor drive belt from the end of the motor drive pulley 6 Loosen the rear roller tensioning bolts 7 Remove the front roller mounting bolts and motor cover brackets 2 8 Lift the front roller out of its frame mount slip off the motor drive belt from the pulley and discard the belt 9 Install new motor drive belt ...

Page 33: ... 3 Disconnect P3 connector at the back of the motor 4 Disconnect P6 1 red and P6 2 black power supply connectors at the circuit board 5 Disconnect P5 1 and bottom lead on circuit breaker 6 Loosen the motor mounting nuts then the motor belt tensioning screw Move the motor mounting plate towards the rear roller to relieve belt tension 7 Remove the drive motor belt off the end of the pulley 8 Remove ...

Page 34: ...motor mounting nuts on the motor mount support plate 5 Turn the motor belt tensioning screw counterclockwise to move the motor mounting plate towards the rear roller to relieve belt tension 6 Remove the front roller mounting bolts 2 lock washers 2 motor cover mounting brackets 2 7 Lift out the roller from the striding belt and remove the motor drive belt 8 Install new front roller in reverse order...

Page 35: ...6 Remove the deck screws 4 7 Remove the rear roller mounting bolts 8 If necessary raise up the deck a little to clear the rear roller guards 2 then lift the rear roller out from the striding belt 9 Install new rear roller in reverse order of removal Make sure to adjust the striding belt tension Refer back to belt adjustment in this section NOTE Before installing a new rear roller scribe an L left ...

Page 36: ...t of the left extrusion and one at the right front extrusion Slide each extrusion back off the extrusion mounting brackets 8 5 Loosen the rear roller tensioning bolts to slacken the striding belt Mark the bolt positions to return the belt to the same tension 6 Remove deck screws 4 at each corner of the deck then lift the deck out of the striding belt being careful of the waxed surface 7 Remove lif...

Page 37: ... lock tape 3 Disconnect P4 connector and the pin 4 connector at P7 on the motor controller board 4 Disconnect the lift motor ground at the bottom of the frame 5 Remove the lift motor pin washer spring and clip 6 Remove the lift motor by rotating it up and around on the axis of the lift nut so that the slotted end of the lift nut aligns with the slots in the retainer bracket 7 Install new lift moto...

Page 38: ...t of the motor cover then lift the rear portion of the motor cover from the dual lock tape 3 Disconnect all electrical connectors from the motor controller board 4 Remove two phillip screws at the bottom of the motor controller mounting bracket and lift out the motor controller from the frame 5 5 5 5 Install new motor controller in reverse order Motor Controller Motor Controller Screw Motor Contro...

Page 39: ... unit then unplug the line cord at the wall outlet 2 Tilt the unit over on its side 3 Loosen the jam nut 4 Remove the adjusting leveler by turning it counterclockwise 5 5 5 5 Install new adjusting leveler in reverse order Make sure to level the unit at the rear roller Lay at least a 6 level across the rear roller With the unit level secure the jam nut up against the leveler frame Leveler Jam nut ...

Page 40: ... unplug the line cord at the wall outlet 2 Remove 12 screws from the back of the console and lift out the overlay assembly 3 Disconnect the ribbon cables main wire harness and telemetry connector from the back of the display console 4 Remove the display board PCB 5 5 5 5 Install new display board in reverse order Telemetry Console Display PCB Overlay Assembly Console Back Cover Guard Section III ...

Page 41: ... the wall outlet 2 Remove 12 screws from the back of the console and lift out the overlay assembly 3 Disconnect the telemetry connector at the telemetry receiver unit 4 Remove the telemetry receiver and heart rate cable from the console 5 5 5 5 Install new telemetry receiver in reverse order making sure to orientate round mark downward as shown Heart Rate Cable Telemetry Unit Mark must face down F...

Page 42: ...oard 6 Pull out the main wire harness from either end of the left side rail and discard INSTALLATION 1 Feed the 10 pin connector end of the new main wire harness through the top of the user left upright Lower and fish it out from the bottom access hole in the user left upright NOTE One method to install new cable is to attach a piece of string to the one end of the oldcable and one end to the new ...

Page 43: ...rn OFF the unit then unplug the line cord at the wall outlet 2 Remove the console 3 Disconnect the ribbon cable 4 Remove two 2 screws from the back of the module buttons 5 Remove the back of the cover and disconnect membrane from main console 6 Remove the membrane switch 7 Install the new membrane switch and the module buttons in reverse order Membrane Switch Module Buttons ...

Page 44: ...lug the line cord at the wall outlet 2 Remove the back cover 3 Disconnect all cable connectors from the overlay bezel 4 Remove the heart rate cable receiver foam module button and PCB from the overlay bezel Discard the overlay bezel 5 Install new overlay bezel making sure to reattach items listed in step 4 in reverse order Section III Telemetry Overlay Assembly Console Display PCB Console Back Cov...

Page 45: ...ing bolts from the top handrail spacer Four 4 long and two 2 short 4 Remove the top handrail spacers 5 Remove the four 4 long mounting bolts from the bottom handrail spacers 6 Remove the spacers and handrails 7 7 7 7 Install the handlerails and crossbar in reverse order NOTE Keep all screws loose until all parts are assembled Once assembled then tighten Long Mounting Bolts 4 Short Mounting Bolts 2...

Page 46: ...Section 3 21 Life Fitness T Series Consumer Treadmills NOTES Section III ...

Page 47: ...Section 4 1 Life Fitness T Series Consumer Treadmills SECTION IV ELECTRONIC OVERVIEW AND WIRING BLOCK DIAGRAM Section IV ...

Page 48: ...a display and communicates with the Motor Control module Connector and Pin Functions Connector Location Pin Functional Description 1 ESD ground 2 Switch return 3 3 Switch strobe 1 4 Switch return 2 5 Switch strobe 3 6 Switch strobe 2 7 Switch return 1 8 Switch strobe 1 9 Switch return 0 10 Switch strobe 0 P1 is a 11 pin connector is used to connect to the membrane switch to the console 11 ESD grou...

Page 49: ...cation Pin Functional Description 1 5 Vdc 2 Polar signal P3 is a 3 pin connector used to connect the polar receiver module to the console 3 Ground 1 Motor control select 2 TXD 3 CLK 4 RXD 5 Test 6 Relay enable 7 8 Volts DC 8 8 Volts DC 9 8 Volts return P4 is an 10 pin phone connector 10 8 Volts return Section IV 1 10 ...

Page 50: ...es and refreshes the status LEDs data display and communicates with the Motor Control module Connector and Pin Functions Connector Location Pin Functional Description 1 ESD ground 2 Switch return 4 3 Switch strobe 1 4 Switch return 3 5 Switch strobe 3 6 Switch return 1 7 Switch strobe 2 8 Switch return 2 9 Switch strobe 1 10 Switch return 1 11 Switch return 0 12 Switch strobe 0 P1 is a 13 pin conn...

Page 51: ...OVERVIEW T3 T5 Console Continued Connector and Pin Functions Connector Location Pin Functional Description 1 Motor control select 2 TXD 3 CLK 4 RXD 5 Test 6 Relay enable 7 8 Volts DC 8 8 Volts DC 9 8 Volts return P4 is an 10 pin phone connector 10 8 Volts return 1 10 ...

Page 52: ...s its bus voltage from the console through the emergency pull switch This relay can be energized by having the emergency pull switch is in its proper place Opening of the relay does not remove power to the console or the logic on the motor control board but will interrupt power to the lift and drive motors Connector and Pin Functions Connector Location Pin Functional Description LED 1 Main loop mo...

Page 53: ...used to link to from the console to the motor controller 10 Ground 1 RPM 2 Isolated ground P3 is used to link the RPM sensor to the motor controller 3 5 Vdc 1 Down 2 AC hot 3 UP P4 is used to link the lift motor to the motor controller 4 Not used 1 120 Vac 2 Neutral P5 supplies line current to the motor controller 3 Ground 1 Positive P6 supplies the drive motor with direct current 2 Negative 1 SW1...

Page 54: ...Section 4 8 Life Fitness T Series Consumer Treadmills ELECTRONIC OVERVIEW BLOCK DIAGRAM ...

Page 55: ...Section 4 9 Life Fitness T Series Consumer Treadmills NOTES Section IV ...

Page 56: ...Section 5 1 Life Fitness T Series Consumer Treadmills SECTION VI MISCELLANEOUS INFORMATION Section V ...

Page 57: ...ISPLAY CONSOLE ASSEMBLY Hardware Inspect Overlay Clean Inspect Emergency Switch Key Clean Inspect HANDLEBAR ASSEMBLY Hardware Inspect Handlebar Inspect Side Hand Rails Inspect FRAME ASSEMBLY Hardware Inspect Motor Cover Clean Motor Electronic Compartment Vacuum Clean Inspect Drive Belt Inspect Leg Levelers Inspect Adjust Front Roller Inspect Rear Roller Inspect ...

Page 58: ...upport D Remove the ship kit box E from the treadmill deck and set aside Remove the back end support F 4 Remove the plastic wrap from the treadmill 5 Carefully lift the rear of the treadmill and slowly roll the unit forward off of the base tray NOTE BE SURE NOT TO DAMAGE THE LINE CORD WHEN MOVING THE TREADMILL OFF OF THE BASE TRAY 6 Follow the Assembly Instructions included in the parts bag to com...

Page 59: ...umidity Þ DO verify the contents of the delivery carton against the accompanying parts listing prior to setting the cartons and shipping material aside If any parts are missing contact Life Fitness Customer Support Services at the number listed on the back page of this assembly instruction booklet Save the shipping cartons in case of return Þ DO read the entire Operation Manual prior to attempting...

Page 60: ...els T5 T5i Only 5 TOP HANDRAIL SPACER Qty 2 6 MOUNTING SCREW SHORT Model T5 T5i Qty 4 1 4 20 x 3 Model T3 T3i Qty 2 7 MOUNTING SCREW LONG Model T5 T5i Qty 8 1 4 20 x 4 25 Model T3 T3i Qty 4 8 BOTTOM HANDRAIL SPACER Qty 2 Models T5 T5i Only 9 HANDRAIL CROSSBAR Qty 1 Models T5 T5i Only 10 UPRIGHT MOUNTING BOLT Qty 4 3 8 16 x 3 25 11 HANDRAIL Qty 1 Models T3 T3i Only 12 STOP CORD Qty 1 13 MOTOR COVER...

Page 61: ...Section 5 6 10 4 6 8 7 5 11 7 6 5 3 2 1 3 5 4 9 8 ...

Page 62: ...NOT TO DAMAGE THE WIRE HARNESS C WHEN ROUTING IT THROUGH THE USER LEFT UPRIGHT 1 NOTE BE CAREFUL NOT TO PINCH THE WIRE HARNESS C WHEN LOWERING THE DISPLAY CONSOLE ASSEMBLY 3 ONTO THE USER LEFT UPRIGHT 1 4 MODELS T3 AND T3i ONLY Models T5 and T5i Skip to Step 5 Locate the HANDRAIL 11 and one TOP HANDRAIL SPACER 5 On the user right side of the HANDRAIL insert a SHORT MOUNTING BOLT 6 through the bott...

Page 63: ... 10 PIN CONNECTOR 10P of the WIRE HARNESS C that was fed into the USER LEFT UPRIGHT through the BOTTOM CABLE ROUTING HOLE F of the USER LEFT UPRIGHT Carefully pull the excess wire from within the USER LEFT UPRIGHT Plug the 10 PIN CONNECTOR into the CONTROL BOARD G located in the MOTOR COMPARTMENT H Feed any excess wire back into the USER LEFT UPRIGHT NOTE BE CAREFUL NOT TO DAMAGE THE WIRE HARNESS ...

Page 64: ...tion the MOTOR COVER A back over the MOTOR COMPARTMENT E and secure the MOTOR COVER to the FRAME B using the two MOTOR COVER SCREWS 13 Tighten the screws securely NOTE BE CAREFUL NOT TO PINCH THE WIRE HARNESS C WHEN REPLACING THE MOTOR COVER A 13 Place the stop cord 12 in the proper location PRE OPERATION CHECKLIST ü Ensure that all fasteners are tight ü Make sure the STRIDING BELT is properly ten...

Page 65: ...ng 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 66: ...ND 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 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 Section VI ...

Page 67: ...Section 5 12 Life Fitness T Series Consumer Treadmills NOTES ...