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Life Fitness Arc Trainer Service Manual

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Life Fitness Arc Trainer
Service Manual
REV August 30, 2022

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Summary of Contents for Life Fitness Arc Trainer

  • Page 1 Life Fitness Arc Trainer Service Manual REV August 30, 2022...
  • Page 3 Latin America and Caribbean* Spain Hong Kong Life Fitness, LLC Life Fitness IBERIA Life Fitness Asia Pacific LTD 10601 W Belmont Ave C/Frederic Mompou 5,1º1ª 26/F, Global Trade Square Franklin Park, IL 60131 U.S.A. 08960 Sant Just Desvern Barcelona...
  • Page 4 User and Service Documents Link https://lifefitness9512.zendesk.com/hc/en-us https://www.lftechsupport.com/web/document-library/documents Additional information is available online using the links above. ‫أ علاه‬ ‫إل ر إبط‬ ‫باستخدإم‬ ‫إ لإ ن تر نت‬ ‫على‬ ‫إضافية‬ ‫معلومات‬ ‫تتوفر‬ 点击上面的链接可在线获取更多信息。 Flere oplysninger er tilgængelige online gennem linket ovenfor. Bijkomende informatie is online beschikbaar via bovenstaande link.

  • Page 5: Table Of Contents

    © Copyright , Life Fitness, LLC. All Rights Reserved. Life Fitness, Hammer Strength, Cybex, ICG and SCIFIT are registered trademarks of Life Fitness, LLC and its affiliated companies and subsidiaries. Disclaimer: Images and specifications are current as of the date of publication and are subject to change.

  • Page 6: Safety Instructions

    1. Safety Safety Instructions Read all instructions before use. Please take special note of the following safety instructions and important points prior to choosing a location and beginning assembly of the product. WARNING: Health-related injuries may result from incorrect or excessive use of exercise equipment. Life Fitness Family of Brands STRONGLY recommends seeing a physician for a complete medical exam before undertaking an exercise program, particularly if the user has a family history of high blood pressure or heart disease, is over the age of 45, smokes, has high cholesterol, is obese, or has not exercised regularly in the past...
  • Page 7 • Always follow the console instructions for proper operation. • This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience or knowledge unless they have supervision or been given instruction concerning the use of the appliance by a person responsible for their safety.

  • Page 8: Introduction

    Life Fitness, Hammer Strength, and ICG. • http://www.lifefitness.com/parts service parts ordering for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG products along with warranty parts ordering and technician requests. • https://lfworld.lifefitness.com easy to find Knowledge Base articles with answers to frequently asked questions and product support documentation for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG.

  • Page 9: Maintenance

    3. Maintenance Preventive Maintenance Tips LIFE FITNESS products are backed by the engineering excellence and reliability of LIFE FITNESS and are one of the most rugged and trouble-free pieces of exercise equipment on the market today. NOTE: Safety of the equipment can be maintained only if the equipment is examined regularly for damage or wear.

  • Page 10: Drive Belts

    Drive Belts Remove Front Access Cover 1. Remove screws securing front access cover using a Phillips screwdriver. Description Qty. Screw Front Access Cover 2. Remove access cover. WARNING: Burn hazard. Do not touch flywheel until cool. Inspect Drive Belts There are two drive belts that may become loose, worn or cracked. Unless the belts have been removed and not replaced properly, it is unlikely the belts will come loose or need to be re-tensioned.
  • Page 11 3. Test unit for proper operation. Page 9 of 79...

  • Page 12: Theory Of Operation Overview

    The Life Fitness Arc Trainer with a ST, SE3, or SE3HD console always require a 24 VDC power supply. The Life Fitness Arc Trainer with a C or X console are self powered, but can use an optional 12 VDC 5 AMP Power Supply (same used with TV).

  • Page 13: Resistance Control Board

    Resistance Control Board (RCB) The RCB contains the Arc Trainer’s fundamental electronics and resides inside the front shrouding behind a metal cover. The RCB inputs power from the generator and / or attached power supply and converts it to voltages needed to run the electronics, apply braking force and operate the incline motor.

  • Page 14: How To's

    5. How To's Knowledge Base Knowledge Base for more detailed information. Battery Replacement Tools Required: • Phillips screwdriver • Needle nose pliers Remove front access cover 1. Remove screws securing front access cover using a Phillips screwdriver. Item Description Qty. Screw Front access cover 2.
  • Page 15 Remove battery 1. Remove screw securing battery bracket using a Phillips screwdriver. Item Description Battery Screw Battery bracket Red (+) and Black (-) battery terminals 2. Remove red (+) and black (-) female terminals from battery. Pull at terminal and not wire. NOTE: Needle nose pliers may be needed if unable to remove terminal by hand.
  • Page 16 3. Plug all cables into control board. Item Description Qty. Cable tie Battery cable Incline motor cable Controller cover Control Board Screw Install front access cover Do not over tighten screws. 1. Place front access cover in place. Item Description Qty.

  • Page 17: Replacement

    Brake Generator Assembly Replacement Tools Required: • 3/16” Allen wrench • 5/16" Allen wrench • Phillips screwdriver • Long Phillips screwdriver • 1/2” Socket wrench • 9/16” Socket wrench • Loctite ® #242, Blue • Loctite ® #271, Red • Straight edge •...
  • Page 18 Remove linkage rods 1. Remove socket head cap screw (SHCS), flat washer, cap and spacer securing linkage rod using a 3/16” Allen wrench. Item Description Qty. Screw, SHCS .250-20 x .75 Flat washer Spacer Linkage rod 2. Lay linkage rod down on frame. Place a clean cloth in between linkage rod and frame to prevent scratches. 3.
  • Page 19 2. Remove three screws securing right shroud in place using a long Phillips screwdriver. 3. Remove both shrouds. Remove Brake Generator 1. Unplug brake generator from resistance control board. 2. Loosen lower pivot mounting bolts (HHCS) using a 1/2” socket wrench. This will loosen tension on primary and secondary belts.
  • Page 20 6. Remove brake generator and spacer from frame. Install Brake Generator 1. Apply Red Loctite ® #271 to four bolts. Item Description Brake Generator Spacer Washer Bolt 2. Align spacer with brake generator. 3. Install four bolts and washers securing brake generator to frame using a 5/16" Allen wrench. Torque to 120 lb-in. 4.
  • Page 21 7. Tighten one HHCS a few turns then tighten the other HHCS a few turns using a 1/2” socket wrench. Alternate until both HHCS are secure. Verify that both pulleys are aligned properly using a straight edge. The straight edge must be no more than 1/16” from pulley edge. Item Description Qty.
  • Page 22 Install crank covers 1. Inspect crank arm mounting. Crank arm should be flush with crank shaft. Adjust with 9/16” socket wrench if needed. NOTE: Crank shaft bolt must be tightened to 30 lbs-ft. Item Description Qty. Screw Crank cover Crank arm Flush mount Crank shaft 2.
  • Page 23 Install front access cover Do not over tighten screws. 1. Place front access cover in place. Item Description Qty. Screw Front access cover 2. Install screws using a Phillips screwdriver. Complete Installation Operate unit at all levels to verify proper operation. Page 21 of 79...

  • Page 24: Brake Generator Assembly

    Contact Heart Rate Grips Replacement - Lower Body Tools Required: • Phillips screwdriver • Side cutter • Tape Time: 30 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard. • Unplug unit and let sit 10 minutes before cleaning or performing maintenance. •...
  • Page 25 3. Disconnect the red and black heart rate wires from each grip. 4. Repeat steps for opposite handle. 5. Remove heart rate cables from original weldment. Install Heart Rate Cable 1. Unplug heart rate cable from console. Item Description Right Heart Rate Cable Left Heart Rate Cable Heart Rate Connector Top Hole...
  • Page 26 Install Rear Cover 1. Install grounding screw securing console assembly to console weldment using a Phillips screwdriver. Item Description Console Assembly Console Weldment Console Back Cover Screw, Pan Head Phillips, M5 x 0.8 x 14 Grounding Screw, Pan Head Phillips, M5 x 0.8 x 14 NOTE: Not all consoles include a grounding screw.

  • Page 27: Contact Heart Rate Grips Replacement - Total Body

    Contact Heart Rate Grips Replacement - Total Body Tools Required: • Phillips screwdriver • Flat head screwdriver • Side cutter • Tape Time: 30 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard. • Unplug unit and let sit 10 minutes before cleaning or performing maintenance. •...
  • Page 28 4. Tape the heart rate cable connections of the new cable to the cut end of the old cable. NOTE: Verify the connection is secure. 5. Pull the old cable through bottom of handle until end of the new cable is up to the top of handle opening. 6.

  • Page 29: Display Cable

    Display Cable Replacement Tools Required: • Phillips screwdriver • Stubby Phillips screwdriver Time: 30 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard. • Unplug unit and let sit 10 minutes before cleaning or performing maintenance. •...
  • Page 30 Remove Accessory Tray Top Remove the two screws securing the accessory tray top to the accessory tray base using a stubby Phillips screwdriver. Item Description Qty. Accessory Tray Top Accessory Tray Base Screw, Pan Head Phillips, 8-16 x .50" Remove Accessory Tray Base Remove the four screws securing the accessory tray base to the frame using a stubby Phillips screwdriver.
  • Page 31 4. Plug display cable into base. Connections include: Coax cable, heart rate and keypad switch cable, base signal cable , and console to base power cable. Install Cables to Console Plug the console cables into the console. SE3 Console Item Description Cable, HDMI Cable, Ethernet...
  • Page 32 Install Accessory Tray Base Install the four screws securing accessory tray base to frame using a Phillips screwdriver. Item Description Accessory tray base Frame Screws Install Accessory Tray Top Install screws securing accessory tray top to accessory tray base using a stubby Phillips screwdriver. Item Description Qty.
  • Page 33 Install Rear Cover 1. Install grounding screw securing console assembly to console weldment using a Phillips screwdriver. Item Description Console Assembly Console Weldment Console Back Cover Screw, Pan Head Phillips, M5 x 0.8 x 14 Grounding Screw, Pan Head Phillips, M5 x 0.8 x 14 NOTE: Not all consoles include a grounding screw.

  • Page 34: Handle Assembly

    Handle Assembly Replacement Tools Required: • 3/16” Allen wrench • 7/32” Allen wrench (2) • Torque wrench Time: 30 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard. • Unplug unit and let sit 10 minutes before cleaning or performing maintenance. •...
  • Page 35 Remove Handle Assembly 1. Remove screw and washer from the handle assembly using two 7/32” Allen wrenches. Item Description Screw Washer Handle Assembly, Left Pivot Pin Assembly 2. Slide pivot pin assembly out and remove handle assembly. Install Handle Assembly 1.
  • Page 36 3. Install screw, flat washer, linkage rod cap, and spacer securing arm handle linkage to handle assembly using a 3/16" Allen wrench. Item Description Screw, Socket Head, .250-20 Loctite #242 Washer, Flat Linkage Rod Cap Spacer, Flange Handle Assembly, Left Arm Handle Linkage, Left 4.

  • Page 37: Linkage Rods

    Linkage Rods Replacement Tools Required: • 3/16” Allen wrench • Torque wrench Time: 20 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard. • Unplug unit and let sit 10 minutes before cleaning or performing maintenance. •...
  • Page 38 Plug in power cord Plug power cord into power outlet. Complete Installation Operate unit at all levels to verify proper operation. Page 36 of 79...

  • Page 39: Primary Drive Belt

    Primary Drive Belt Replacement Tools Required: • Clean cloth • 9/16” Socket wrench • Phillips screwdriver • 9/16” Open end wrench • Long Phillips screwdriver • Torque wrench • 3/16” Allen wrench • Straight edge • 1/2” Socket wrench Time: 60 minutes Disconnect Power Source Unplug power cord from power outlet.
  • Page 40 Remove crank covers 1. Remove both screws securing crank cover using a Phillips screwdriver. Item Description Qty. Screw, Pan head Phillips 10/32 x .62 Crank cover Crank arm Flush mount Crank shaft 2. Remove crank cover. 3. Repeat steps for other crank cover. Remove shrouds 1.
  • Page 41 Remove lower pulley assembly 1. Remove the two Hex Head Cap Screws (HHCS), two lock washers and two flat washers from the lower pulley shaft using a 1/2” socket wrench. Item Description Qty. HHCS Lock washer Flat washer Lower pulley shaft Drive belt 2.
  • Page 42 2. Install two bolts, four washers, and two nuts to left pillow block using a 9/16” socket wrench and a 9/16” open end wrench. Item Description Qty. Washers Pillow block Bolt 3. Install bolts on the right pillow block. Install lower pulley assembly 1.
  • Page 43 Tension Drive Belt Tighten one HHCS a few turns then tighten the other HHCS a few turns using a 1/2” socket wrench. Alternate until both HHCS are secure. NOTE: Verify that both pulleys are aligned properly using a straight edge. The straight edge must be no more than 1/16”...
  • Page 44 Install crank covers 1. Inspect crank arm mounting. Crank arm should be flush with crank shaft. Adjust with 9/16” socket wrench if needed. NOTE: Crank shaft bolt must be tightened to 30 ft-lbs (40.67 Nm). Item Description Qty. Screw, Pan head Phillips 10/32 x .62 Crank cover Crank arm Flush mount...
  • Page 45 Install front access cover Do not over tighten screws. 1. Place front access cover in place. Item Description Qty. Screw Front access cover 2. Install screws using a Phillips screwdriver. Plug in power cord Plug power cord into power outlet. Complete Installation Operate unit at all levels to verify proper operation.

  • Page 46: Pulley And Crank Shaft

    Pulley and Crank Shaft Replacement Tools Required: • 3/16” Allen wrench • Clean cloth (2) • Phillips screwdriver • 7/32” Allen wrench • 9/16” Open end wrench • Long Phillips screwdriver • 1/2” Socket wrench • Torque wrench, 7/32" Allen wrench •...
  • Page 47 Remove linkage rods 1. Remove socket head cap screw (SHCS), flat washer, cap and spacer securing linkage rod using a 3/16” Allen wrench. Item Description Qty. Screw, SHCS .250-20 x .75 Flat washer Spacer Linkage rod 2. Lay linkage rod down on frame. Place a clean cloth in between linkage rod and frame to prevent scratches. 3.
  • Page 48 2. Remove crank arms from crank arm shaft. Remove shrouds 1. Remove seven screws securing left shroud in place using a long Phillips screwdriver. Item Description Qty. Screw Left shroud 2. Remove three screws securing right shroud in place using a long Phillips screwdriver. 3.
  • Page 49 Remove crank shaft assembly 1. Remove the four bolts, eight flat washers and four nuts securing crank shaft assembly to frame using a 9/16” socket wrench and a 9/16” open end wrench. Item Description Qty. Crank shaft assembly Primary belt Pillow block Alignment pin Flat washer...
  • Page 50 Tension Drive Belt Tighten one HHCS a few turns then tighten the other HHCS a few turns using a 1/2” socket wrench. Alternate until both HHCS are secure. NOTE: Verify that both pulleys are aligned properly using a straight edge. The straight edge must be no more than 1/16”...
  • Page 51 Install crank arms 1. Slide each crank arm in place. Item Description Qty. Crank arm shaft Crank arm Washer HHCS The face of each crank arm should be flush with the end of each shaft. 2. Tighten HHCS on each crank arm using a torque wrench with 9/16” socket. NOTE: HHCS must be tightened to a minimum of 30 lbs-ft.
  • Page 52 Install linkage rods 1. Install linkage rod on crank arm. Item Description Qty. Screw, SHCS .250-20 x .75 Flat washer Spacer Linkage rod 2. Place a drop of Loctite ® #242 on SHCS and place another drop of Loctite ® #242 into threads of shaft.

  • Page 53: Replacement

    Front Foot Plate Arm Replacement Tools Required: • Phillips screwdriver • 3/16” Allen wrench • 5/32” Allen wrench • 7/32” Allen wrench • Torque wrench • Rubber mallet Time: 30 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard.
  • Page 54 2. Remove foot plate from front and rear foot plate shafts. Page 52 of 79...
  • Page 55 Remove Side Covers - Lower Body 1. Open gasket and remove from side handle. Item Description Gasket Side Handle, Left Cover, Rear, Lower, Left 2. Remove screws securing top side cover to frame using a Phillips screwdriver. 3. Remove screws from grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19...

  • Page 56: Front Foot Plate Arm

    Remove Side Covers - Total Body 1. Remove screws securing top side cover to frame using a Phillips screwdriver. 2. Remove screws from grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19 Screw, Pan Head Phillips, 10-24 x .75"...
  • Page 57 Install front foot plate arm 1. Position front foot plate arm in place. Item Description Qty. BHSCS Washer Front foot plate arm Loctite ® #242 2. Place a drop of Loctite on the BHSCS and another drop inside the shaft into where the BHSCS will be tightened. 3.
  • Page 58 3. Install screws into grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19 Screw, Pan Head Phillips, 10-24 x .75" Side Cover, Top Side Cover, Bottom 4.
  • Page 59 2. Install grommets to top side cover. Item Description Grommet, Nylon Side Cover, Top 3. Install screws into grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19 Screw, Pan Head Phillips, 10-24 x .75"...
  • Page 60 Install front arm handle linkage 1. Install arm handle linkage to handle. Description Qty. Screw Flat washer Spacer Arm handle linkage Handle 2. Place a drop of loctite on threads of screw. 3. Place another drop of loctite into the threads of the shaft. 4.

  • Page 61: Replacement

    Rear Foot Plate Arm Replacement Tools Required: • Phillips screwdriver • 3/16” Allen wrench • 5/32” Allen wrench • 7/32” Allen wrench • Torque wrench • Rubber mallet Time: 30 minutes Disconnect Power Source Unplug power cord from power outlet. WARNING: Shock and electrocution hazard.
  • Page 62 2. Remove foot plate from front and rear foot plate shafts. Page 60 of 79...
  • Page 63 Remove Side Covers - Lower Body 1. Open gasket and remove from side handle. Item Description Gasket Side Handle, Left Cover, Rear, Lower, Left 2. Remove screws securing top side cover to frame using a Phillips screwdriver. 3. Remove screws from grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19...

  • Page 64: Rear Foot Plate Arm

    Remove Side Covers - Total Body 1. Remove screws securing top side cover to frame using a Phillips screwdriver. 2. Remove screws from grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19 Screw, Pan Head Phillips, 10-24 x .75"...
  • Page 65 Install rear foot plate arm 1. Position rear foot plate arm in place. Item Description Qty. BHSCS Washer Rear foot plate arm Loctite ® #242 2. Place a drop of Loctite on the BHSCS and another drop inside the shaft into where the BHSCS will be tightened. 3.
  • Page 66 3. Install screws into grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19 Screw, Pan Head Phillips, 10-24 x .75" Side Cover, Top Side Cover, Bottom 4.
  • Page 67 2. Install grommets to top side cover. Item Description Grommet, Nylon Side Cover, Top 3. Install screws into grommets securing bottom side cover to top side cover using a Phillips screwdriver. Item Description Screw, Pan Head Phillips, M4.2 x 0.7 x 19 Screw, Pan Head Phillips, 10-24 x .75"...
  • Page 68 Install front arm handle linkage 1. Install arm handle linkage to handle. Description Qty. Screw Flat washer Spacer Arm handle linkage Handle 2. Place a drop of loctite on threads of screw. 3. Place another drop of loctite into the threads of the shaft. 4.

  • Page 69: Troubleshooting

    6. Troubleshooting Knowledge Base Knowledge Base for more detailed information. Troubleshooting the Polar ® Heart Rate Chest Strap Heart rate reading is erratic or absent entirely Probable Cause Corrective Action Belt transmitter electrodes are not wet enough to pick up Wet the belt transmitter electrodes.

  • Page 70: Incline Not Working

    Incline Not Working Mechanical or Voltage issues • Make sure the connector is connected to the board, and connector is in good shape. • Check battery voltage, 12 VDC. • Replace battery. Software issues For Arc Trainers with an SE3HD or Discover ST console where the incline is not working may be a result of the battery not charging during use.

  • Page 71: Manual

    7. Software Refer to Console Service Manual This product uses multiple consoles. Refer to the specific Console Service Manual for more detailed information. List of consoles are found in the Related Products section of the Introduction chapter. Page 69 of 79...

  • Page 72: Diagnostics

    8. Diagnostics Refer to Console Service Manual This product uses multiple consoles. Refer to the specific Console Service Manual for more detailed information. List of consoles are found in the Related Products section of the Introduction chapter. Page 70 of 79...

  • Page 73: Error Code List

    9. Error code list Error codes notify user of a problem condition and are displayed on the console. Error codes can also help to indicate the part of the unit most likely to be causing the problem. Refer to Console Service Manual This product uses multiple consoles.

  • Page 74: Network Information

    10. Network Information Refer to Console Service Manual This product uses multiple consoles. Refer to the specific Console Service Manual for more detailed information. List of consoles are found in the Related Products section of the Introduction chapter. Page 72 of 79...

  • Page 75: Schematics

    Life Fitness, Hammer Strength, and ICG. • http://www.lifefitness.com/parts service parts ordering for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG products along with warranty parts ordering and technician requests. • https://lfworld.lifefitness.com easy to find Knowledge Base articles with answers to frequently asked questions and product support documentation for Life Fitness, Cybex, SCIFIT, Hammer Strength, and ICG.

  • Page 76: Advanced Schematic

    Advanced Schematic Page 74 of 79...

  • Page 77: Basic Schematic

    Basic Schematic Page 75 of 79...

  • Page 78: Led Chart

    12. LED Chart Resistance Control Board LED's LED Color LED Function Normal Mode Notes Green TTL TXD Flashing on Discover, Solid on Indicates board is communicating (base to Hercules. Blinks in phase with logic console) LOW TTL TXD signal. V_Flybk On when pedaling.

  • Page 79: Glossary

    Adjustable supports located under the unit, used to stabilize the unit. Lifepulse ™ Life Fitness' proprietary hardware and software system designed to measure user's heart rate by making electrical contact at user’s palms. Polar Receiver A device directly in front of the operator that monitors heart rate. Designed by the Polar ®...

  • Page 80: Warranty

    Who Pays Transportation and Insurance For Service If the Product or any covered part must be returned to a service facility for repairs, We, Life Fitness Family of Brands, will pay all transportation and insurance charges for the first year. You are responsible for transportation and insurance charge after the first year.

  • Page 81: Effects Of State Laws

    This warranty gives you specific legal rights, and you may have other rights which vary from state to state and country by country. Warranty Information Base 3 years 2 years 1 Year Arc Trainer (Commercial) Electrical and Mechanical Labor Parts Arc Trainer (Consumer / Home) Electrical and Mechanical Parts Warranties outside the U.S. may vary. Page 79 of 79...

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