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Life Fitness 5500HR Service Manual

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Model 5500HR Treadmill
Customer Support Services
SERVICE MANUAL

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Summary of Contents for Life Fitness 5500HR

  • Page 1 Model 5500HR Treadmill Customer Support Services SERVICE MANUAL...
  • Page 2 ©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.
  • Page 3 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.

  • Page 4: Table Of Contents

    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 ........................
  • Page 5 Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: "Slowdown". Belt slips during footfall or desired speed is reduced. Malfunction Probable Cause Corrective Action Insufficient power source. Plug treadmill into a dedicated 120V, Belt slips during footfall 15 amp circuit. (See Operations...

  • Page 6: Troubleshooting Guides

    Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: Noisy Treadmill Malfunction Probable Cause Corrective Action Wax build-up on roller Run unit for 10 hours of ontime use to Knocking sound at rear of distribute wax evenly machine Faulty rear roller bearings.

  • Page 7: Display Does Not Illuminate Or Respond To Input

    Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: Display Does Not Illuminate or Respond To Input Malfunction Probable Cause Corrective Action Plug treadmill into a dedicated 120V, 15 Display does not illuminate Insufficient power source. amp circuit when machine is powered Turn power ON at switch while pressing the Speed Down ∇...

  • Page 8: Unit Resets Randomly

    Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: Unit Resets Randomly Malfunction Probable Cause Corrective Action Unit resets randomly Insufficient power source. Plug treadmill into a dedicated 120V, 15 amp circuit. Damaged line cord. Replace line cord. Line cord improperly seated in Inspect power connection at electrical socket.

  • Page 9: No Power

    Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: No Power Malfunction Probable Cause Corrective Action I/O or On/Off switch. Is unit turned on? No Power Insufficient power source. Plug treadmill into a dedicated 120V, 15 amp circuit. Using a meter, verify power at outlet.
  • Page 10 Unit is not level. Level treadmill by adjusting leveling Striding belt mis-alignment legs. by more than 1/4”. Belt Skewed Replace front roller bolt with Belt skew kit. For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 11: Display Reads Errors

    Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: Display reads Errors Malfunction Probable Cause Corrective Action Loose connections at electrical Verify the plug is seated properly in the Belt Moving Error outlet. electrical outlet. User has overdriven belt. Reset the unit.

  • Page 12: Lift Error

    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 Position the line cord to its proper lift leg assembly position. Perform incline test (See Diagnostics).
  • Page 13 Life Fitness Model 5500HR Treadmill TROUBLESHOOTING GUIDE Symptom: Heart Rate System Does Not Respond, Erratic Heart Rate Reading Symptom Probable Cause Corrective Action HR receiver not installed. Install HR receiver into HR receiver jack No heart rate or display on underside of handlebar tray.
  • Page 14 Life Fitness Model 5500HR Treadmill NOTES:...

  • Page 15: Diagnostic Tests

    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...
  • Page 16 ⇒ 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.
  • Page 17 ⇒ 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.
  • Page 18 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.

  • Page 19: How To

    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.

  • Page 20: Heatsink Control Board

    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.
  • Page 21 Life Fitness Model 5500HR Treadmill HOW TO REMOVE AND REPLACE THE HEATSINK CONTROL BOARD (Continued) CPU CONNECTION...
  • Page 22 Life Fitness Model 5500HR Treadmill How To... REMOVE AND REPLACE THE DRIVE MOTOR BELT Tools Required: Phillips Screwdriver, Socket Set 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.
  • Page 23 How To... REMOVE AND REPLACE THE DRIVE MOTOR BELT (Continued) Tools Required: Phillips Screwdriver, Socket Set Step 12 Position the drive pulley side of the FRONT ROLLER ASSEMBLY in the available hole and the left side of the FRONT ROLLER ASSEMBLY in the FRAME slot closest to the front of the unit. Step 13 Reverse Steps 1 through 10 to return all parts to their proper positions.
  • Page 24 Life Fitness Model 5500HR Treadmill How To... REMOVE AND REPLACE THE DRIVE MOTOR ASSEMBLY Tools Required: Phillips Screwdriver, Socket Set 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.
  • Page 25 Life Fitness Model 5500HR Treadmill HOW TO...REMOVE AND REPLACE THE REAR END CAP PANEL 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 three SCREWS from each side of the REAR END CAP PANEL and remove the damaged REAR END CAP PANEL.
  • Page 26 Life Fitness Model 5500HR Treadmill HOW TO...REMOVE AND REPLACE THE FRONT ROLLER ASSEMBLY Tools Required: Phillips screwdriver, hex key wrench set, socket set, open end wrench (1/2”) Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 27 Life Fitness Model 5500HR Treadmill HOW TO...REMOVE AND REPLACE THE REAR ROLLER ASSEMBLY Tools Required: Phillips screwdriver, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.

  • Page 28: Deck

    Life Fitness Model 5500HR Treadmill HOW TO ... REMOVE AND REPLACE THE DECK Tools Required: Phillips screwdriver, hex key wrench set ATTENTION: THE DECK MUST ALWAYS BE REPLACED WHEN INSTALLING A NEW STRIDING BELT. Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 29 Life Fitness Model 5500HR Treadmill HOW TO...REMOVE AND REPLACE THE STRIDING BELT Tools Required: Phillips screwdriver, hex key wrench set, socket set, open end wrench (1/2”) ATTENTION: THE DECK MUST ALWAYS BE REPLACED WHEN INSTALLING A NEW STRIDING BELT. Step 1...
  • Page 30 Life Fitness Model 5500HR Treadmill How To... ADJUST AND TENSION THE STRIDING BELT Tools Required: Hex key wrench set, Phillips screwdriver CAUTION: DO NOT MOVE OR PLACE YOUR HANDS UNDER THE UNIT WHILE THE MACHINE IS PLUGGED INTO AN ELECTRICAL OUTLET.
  • Page 31 Life Fitness Model 5500HR Treadmill How To... ADJUST AND TENSION THE STRIDING BELT (Continued) Tools Required: Hex key wrench set, Phillips screwdriver CAUTION: DO NOT MOVE OR PLACE YOUR HANDS UNDER THE UNIT WHILE THE MACHINE IS PLUGGED INTO AN ELECTRICAL OUTLET.

  • Page 32: Display Console

    Life Fitness Model 5500HR Treadmill HOW TO...REMOVE AND REPLACE THE DISPLAY CONSOLE 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 from the underside of the CONTROL PANEL which secure the DISPLAY CONSOLE in place.
  • Page 33 Life Fitness Model 5500HR Treadmill HOW TO ... REMOVE AND REPLACE THE TELEMETRY UNIT Tools Required: None Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet. Step 2 Carefully squeeze the sides of the TELEMETRY/HEART RATE SENSOR COVER inward to disengage the four tabs from the CONTROL PANEL.
  • Page 34 Life Fitness Model 5500HR Treadmill HOW TO ... REMOVE AND REPLACE THE LIFT ACTUATOR Tools Required: Phillips screwdriver, pliers Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet. Step 2 Remove the MOTOR COVER (See How To...”).
  • Page 35 Life Fitness Model 5500HR Treadmill HOW TO ... REMOVE AND REPLACE THE ON/OFF SWITCH 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 Remove the MOTOR COVER (See How To...”).
  • Page 36 Life Fitness Model 5500HR Treadmill HOW TO ... REMOVE AND REPLACE THE CHOKE Tools Required: Phillips screwdriver, socket and wrench set WARNING: FAILURE TO OBSERVE SAFE 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.
  • Page 37 Life Fitness Model 5500HR Treadmill HOW TO ... REMOVE AND REPLACE THE TRANSFORMER Tools Required: Phillips screwdriver, socket and wrench set WARNING: FAILURE TO OBSERVE SAFE 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.
  • Page 38 Life Fitness Model 5500HR Treadmill NOTES:...

  • Page 39: On/Off Switch

    Life Fitness Model 5500HR Treadmill PARTS DESCRIPTION PARTS NOT CALLED PART SERIAL NO. SERIAL NO. ITEM DESCRIPTION PART NUMBERS OUT OR SHOWN NUMBERS 268648 ê 268649 é Drive Motor Assy SK36-00068-0001 Fan: Plastic OK36-01093-0001 Opto sensor w/Bkt Assy AK36-00070-0000 Warranty Card...
  • Page 40 Life Fitness Model 5500HR Treadmill PARTS DESCRIPTION...
  • Page 41 Life Fitness Model 5500HR Treadmill PARTS DESCRIPTION...
  • Page 42 Life Fitness Model 5500HR Treadmill NOTES:...

  • Page 43: Wiring Block Diagram

    Life Fitness Model 5500HR Treadmills WIRING BLOCK DIAGRAM...

  • Page 44: Preventive Maintenance Tips

    Life Fitness Model 5500HR Treadmills PREVENTIVE MAINTENANCE TIPS ITEM WEEKLY MONTHLY QUARTERLY BI-ANNUAL ANNUAL Anti-Static INSPECT Cords REPLACE Console Mounting INSPECT Bolts Frame CLEAN INSPECT Striding Belt CLEAN ( Top ) ( VACUUM ) INSPECT Deck INSPECT Power Cord INSPECT...

  • Page 45: Communicating By Fax

    Life Fitness Model 5500HR Treadmills COMMUNICATING BY FAX If you would like to submit a parts order, or if you need help troubleshooting 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.
  • Page 46 GROUND PARTS ORDER FORM ITEM NO. PART NUMBER DESCRIPTION QUANTITY PRODUCT TROUBLESHOOTING PRODUCT NAME: SERIAL NO. DETAILED DESCRIPTION OF PROBLEM: PRODUCT NAME: SERIAL NO. DETAILED DESCRIPTION OF PROBLEM: TIME RECEIVED: TIME COMPLETED: TECHNICIAN NAME: Life Fitness Model 5500HR Treadmills NOTES:...
  • Page 47 Life Fitness Model 5500HR Treadmills NOTES:...

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