Life Fitness E5 Service Manual
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Life Fitness E5 Service Manual

Total-body elliptical cross-trainers
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E5 TOTAL-BODY ELLIPTICAL
CROSS-TRAINERS
E5-XXXX-0105
SERVICE MANUAL
March 2015

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  • Page 1 E5 TOTAL-BODY ELLIPTICAL CROSS-TRAINERS E5-XXXX-0105 SERVICE MANUAL March 2015...

  • Page 2: Table Of Contents

    Table of Contents INTRODUCTION Using this Manual Warranty Serial Number Location Contact Page Troubleshooting Required Service Tools Preventive Maintenance Schedule ACTIVITY ZONE Error Messages Diagnosing Activity Zone Error Messages Settings Diagnostics THEORIES OF OPERATION HOW TO... Replace the Cup Holder Replace the Upper Rear Console Support Cover Replace the Console Replace the Deadshaft Covers...

  • Page 3: Introduction

    This service manual provides safe and effi cient test and service procedures for the Life Fitness E5 consumer cross-train- ers. The E5 cross-trainer comes with two optional consoles: the Go and the Track Plus. Please refer to the respective Go or Track Plus Service Manuals for information regarding diagnostics, errors displayed on the console, troubleshooting the console and how to replace parts on the console.

  • Page 4: Warranty

    If the Product or any warranted part must be returned to a numbers). They will tell you how to get a replacement part, or, if service facility for repairs, Life Fitness will pay all shipping and necessary, arrange for service where your Product is located.

  • Page 5: Serial Number Location

    Introduction: Serial Number Location To speed Life Fitness Customer Support Service’s response, please be prepared to provide the following information: • Serial number (starts with the product code followed by 12 numbers) • Model number • Part name and number to order (if known) •...
  • Page 6 Operating Hours: 9.00h-17.00h (JAPAN) Service Email: customersupport@lifefi tness. kundenberatung@lifefi tness.com China and Hong Kong Operating Hours: 08:30-16.30.h (MEZ) Sales/Marketing Email: Life Fitness Asia Pacifi c LTD consumerproducts@lifefi tness.com Spain Room 2610, Miramar Tower Operating Hours: 7:00am-6:00pm (CST) Life Fitness IBERIA...

  • Page 7: Troubleshooting

    Introduction: Troubleshooting PROBLEM OBSERVED POSSIBLE CAUSE CORRECTIVE ACTION Unplug the cross-trainer from the wall outlet and measure the line voltage with a multi-me- ter at the outlet. Switch the cross-trainer to an outlet with suffi cient line voltage if necessary. Insuffi...
  • Page 8 PROBLEM OBSERVED POSSIBLE CAUSE CORRECTIVE ACTION Refer to the Go and Track Plus console manuals for full diagnostic steps of the heart rate board. Malfunctioning telemetry There is a mode in Diagnostics in the console receiver where you can test telemetry and contact heart rate.
  • Page 9 PROBLEM OBSERVED POSSIBLE CAUSE CORRECTIVE ACTION Leveler nut not tight against Tighten leveler nut. frame Excessive grinding, rubbing, Noisy pedal lever bearings Replace pedal lever assembly. knocking noises when pedal Noisy user arm bearings Replace user arm bearings. levers rotate under load Noisy idler bearings Replace the idler assembly.
  • Page 10 Service Manuals. Error messages E1, E2, E3, E4, Refer to the Activity Zone Error Message Issue with the electrical stride E5, or E6 displayed in the adjustment system. section in this manual. Activity Zone. The console mounting bracket most likely shift- ed during customer assembly.

  • Page 11: Required Service Tools

    Note: Specialized tools may be required to complete some service procedures safely (see list below). Using tools improperly can result in damage to equipment or personal injury. WARNING: Wearing a static discharge device (ESD strap, Life Fitness part #171-419) when servicing electronic components. Electrostatic discharge can damage electronic components, either through outright failure or through...

  • Page 12: Preventive Maintenance Schedule

    Introduction: Preventive Maintenance Schedule Item Weekly Monthly Biannually Console Overlay Clean Inspect Bottle Holders Clean Inspect Console Mounting Bolts Inspect Frame Clean Inspect Plastic Covers Clean Inspect Lifepulse Sensors Clean / Inspect Pedals and Straps Clean Inspect...

  • Page 13: Activity Zone

    The drive for the actuators will be turned OFF. E5 - Stuck Key Error in Activity Zone If the Leg Sculptor, Stride Length Up or Stride Length Down keys are stuck closed for over 30 seconds this error will occur.
  • Page 14 On the E5 cross-trainer there are 6 increments to the stride length and each increment takes 6 seconds of travel time. Since the Activity Zone controls the stride motors, it can maintain the motor duty cycle to reduce over actuation.

  • Page 15: Diagnosing Activity Zone Error Messages

    Activity Zone: Diagnosing Activity Zone Error Messages 1. Cycle the power: a. Turn the ON / OFF switch OFF. b. Wait 10 seconds. c. Turn the ON/OFF switch back ON. If functioning normally the actuators should move downward until hitting the home position limit switch.
  • Page 16 The switches have normally closed contacts. So the circuit through the switch is completed when the switch is not actu- ated. When the switch is actuated the circuit will be open and the diagnostic LED for that switch on the control board will be out.
  • Page 17 Use a multimeter to check for continuity on all 4 wires, end to end. Note: If the idler cable has a broken wire it may blow the fuse on the motor control board (see E5 Motor Con- troller Connectors illustration on the next page). The E5 will have no power if this fuse is blown. Replacement fuse is part number REX2WYC which is a 3.15A, 250V, TIME DELAY, 5.20mm x 20.00mm –(BUSSMANN BK/...
  • Page 18 7. If both actuators will not move, check the fuse on the motor control board. Replacement fuse is part number REX- 2WYC which is a 3.15A, 250V, TIME DELAY, 5.20mm x 20.00mm – (BUSSMANN BK/S506-3.15-R or equivalent). E5 Motor Controller Connectors Right actuator motor power...

  • Page 19: Settings

    Activity Zone: Settings Entering the Settings Menu To enter the Settings Menu make sure the Activity Zone is illuminated, but a workout is NOT in progress. Press and hold the Leg Sculptor and Stride Down keys for three plus seconds. The display will beep consecutively three times and display the text “settings”...

  • Page 20: Diagnostics

    Activity Zone: Diagnostics Entering the Activity Zone Diagnostics Menu Press and Hold the Leg Sculptor key and Stride Length Up key for 5 plus seconds. The display will beep three times and the display will be in Photo Shoot Mode. Note: The Activity Zone must be in Idle mode to enter diagnostics.

  • Page 21: Theories Of Operation

    The stride length of the product can be changed by selecting different stride lengths on the Activity Zone. The stride length is controlled by a motor controller inside the E5. The system works by the actuators located in the adjustment links fi...

  • Page 22: How To

    How To... Replace the Cup Holder Tools Required: none Estimated Repair Time: 15 Minutes 1. Place one hand above the cup holder. 2. With the other hand, gently tap the bottom of the cup holder. 3. Lift the cup holder out of the accessory tray. 4.

  • Page 23: Replace The Console

    How To..Replace the Console Console Tools Required: Phillips Screwdriver Estimated Repair Time: 15 Minutes Console 1. Turn the cross-trainer power switch OFF. Support Bracket 2. Unplug the line cord from the wall outlet. 3. Remove the upper rear console support cover (see How To Replace the Upper Rear Console Support Phillips Screws...

  • Page 24: Replace The Deadshaft Covers

    How To..Replace the Deadshaft Covers Tools Required: Phillips Screwdriver Estimated Repair Time: 30 Minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove and save the two Phillips screws that secure the deadshaft covers to each other. Discard the covers. 4.

  • Page 25: Replace The Lower Rear Console Support Cover

    How To..Replace the Lower Rear Console Support Cover Tools Required: Phillips Screwdriver Estimated Repair Time: 15 Minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove the upper rear console sup- port cover (see How To Replace the Console Mounting Bracket Upper Rear Console Support Cover on...

  • Page 26: Replace The Console Mounting Bracket

    How To..Replace the Console Mounting Bracket Tools Required: 17mm Socket Wrench Estimated Repair Time: 15 Minutes Console Mounting 1. Turn the cross-trainer power switch OFF. Bracket 2. Unplug the line cord from the wall outlet. 3. Remove the rear console support covers and console (see How To Replace the Upper Rear Console Support Cover on page 21, How to Replace the Lower Rear Console Support Cover on page 24 and How to Replace the Console on page 22).

  • Page 27: Replace The Ergo Bar Assembly

    How To..Replace the Ergo Bar Assembly Tools Required: Phillips Screwdriver and 5mm Allen Wrench Estimated Repair Time: 30 minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove the console support covers and console (see How To Replace the Upper Rear Console Support Cover on page 21 and How to Replace the Lower Rear Console Support Cover on page 24).

  • Page 28: Replace The Heart Rate Hand Sensors

    How To..Replace the Heart Rate Hand Sensors Tools Required: Phillips Screwdriver Estimated Repair Time: 30 Minutes Heart Rate Hand Sensor 1. Remove and save the two Phillips screws that secure the right or left heart rate hand sensors to the Ergo Bar assembly or the User Arms.

  • Page 29: Replace The Upright Covers

    How To..Replace the Upright Covers Tools Required: Phillips Screwdriver Estimated Repair Time: 15 minutes 1. Remove and save the four Phillips screws that secure either the left or right upright cover to the frame. 2. Remove the upright cover. 3.

  • Page 30: Replace The User Arms

    How To... Replace the User Arms Tools Required: Phillips Screwdriver, small standard screwdriver, 17mm socket wrench Estimated Repair Time: 30 Minutes 1. Remove and save the bolt and washer that secure the user arm to the deadshaft. 2. Remove and save the front moving arm pivot (clevis)covers. Flat Washer Bolt 3.

  • Page 31: Replace The User Handle

    How To..Screws (4) Deadshaft Deadshaft Cover Cover Replace the User Handle Tools Required: Phillips Screwdriver, Metric Allen Wrench Set Estimated Repair Time: 15 minutes 1. Remove the deadshaft covers. 2. Unplug the connectors wrapped around the deadshaft. 3. Remove the 4 bolts that hold the user handle to the rocker arm.

  • Page 32: Replace The Rear Shrouds

    How To..Replace the Rear Shrouds Tools Required: Short Phillips Screwdriver Left Back Rear Shroud Estimated Repair Time: 30 minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. It is best to remove the back shroud before remov- ing the front shroud on each side.

  • Page 33: Replace The Idler With Cable Assembly

    How To..Replace the Idler with Cable Assembly Tools Required: Phillips Screwdriver, 17mm Socket Wrench Estimated Repair Time: 45 minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet 3. Remove and save the fi ve screws that secure the front right rear shroud to the frame. 4.
  • Page 34 6. Remove and save the bolt and washer that secure the idler assembly to the main frame. 7. Pull the cable out of the main frame tube. Remove and save the bolt that secures the other end of the idler assembly to the actuator bracket. 8.

  • Page 35: Replace The Outside Actuator Shroud

    How To..Replace the Outside Actuator Shroud Tools Required: Phillips Screwdriver Estimated Repair Time: 15 minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove and save the fi ve screws that secure the outside actuator shroud to the inside actuator shroud.

  • Page 36: Replace The Actuator Assembly Or Inside Actuator Shroud

    How To..Replace the Actuator Assembly or Inside Actuator Shroud Tools Required: Two Jaw Puller, #2 Phillips Screwdriver, External Snap Ring Pliers, 17mm Wrenches (2) Estimated Repair Time: 30 minutes 1. Raise the stride length to the maximum. 2. Turn the cross trainer power switch OFF. 3.

  • Page 37: Replace The Pedal Lever Assembly

    How To..Replace the Pedal Lever Assembly Tools Required: Phillips Screwdriver, 17mm Socket Wrench Estimated Repair Time: 30 minutes 1. Turn the cross trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove the moving arm pivot (clevis ) cover from the user arm (see How to Replace the Moving Arm Pivot (Clevis) Covers on page 28).

  • Page 38: Replace The Resistance Stepper Motor

    How To..Replace the Resistance Stepper Motor Tools Required: Phillips Screwdriver, 6mm Deep Socket and Ratchet Estimated Repair Time: 60 minutes 1. Turn the cross trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove and save the ten screws that secure both the front and rear shrouds on the right side of the unit. 4.

  • Page 39: Replace The Motor Control Board

    How To..Replace the Motor Control Board Tools Required: Phillips Screwdriver Estimated Repair Time: 30 minutes 1. Turn the cross trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove and save the fi ve screws that secure the front right rear shroud to the frame. 4.

  • Page 40: Replace The Eddy Current Brake Mechanism

    How To..Replace the Eddy Current Brake Mechanism Tools Required: Phillips Screwdriver, 17mm Socket Wrench Estimated Repair Time: 30 minutes 1. Turn the cross trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Remove the rear shrouds (see How To Replace the Rear Shrouds on page 31). 4.
  • Page 41 14. Carefully remove the eddy current brake and its loose side brackets from of the frame. 15. Remove the side brackets. 16. Loosely install the new eddy current brake to the side brackets. Do not install the nut and washer on the left side of the eddy current brake assembly until the drive belt has been re-installed.

  • Page 42: Calibrate The Eddy Current And Servo Motor

    How To..Calibrate the Eddy Current Brake and Servo Motor Tools Required: Phillips Screwdriver, 17mm Socket Wrench, 8mm Open End Wrench Estimated Repair Time: 30 Minutes Procedure 1. Disconnect the power from the machine. LEVEL 1 POSITION 2. Remove shrouds as required. 3.
  • Page 43 How To..Calibrate the Eddy Current Brake and Servo Motor (continued) 6. Screw the adjuster on the brake cable all the way in, then install the end of the cable into the slide block on the eddy current brake. Do not insert the end fi tting of the cable housing into the slot at the bottom of the slide block channel.
  • Page 44 How To..Calibrate the Eddy Current Brake and Servo Motor (continued) 8. Clip the end fi tting of the brake cable housing into the slot at the bottom of the slide block channel. 9. Plug the power back into the machine. The servo motor should move to the Level 1 resistance position after the console initializes.

  • Page 45: Replace The Drive Belt

    How To... Replace the Drive Belt Drive Belt Magnet ic Brake Tools Required: Allen Wrench, Open-End Wrench Estimated Repair Time: 60 Minutes Idler Bracket 1. Turn the cross-trainer power switch OFF. Mark t he locat ion 2. Unplug the line cord from the wall outlet. of t he Idler Bracket 3.

  • Page 46: Replace The Ac Inlet Or On/Off Switch

    How To... Replace the AC Inlet or ON/OFF Switch Tools Required: Phillips Screwdriver, Needle Nose Pliers Phillips Estimated Repair Time: 30 Minutes Screws (4) ON /OFF Switch 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. AC Inlet 3.

  • Page 47: Replace The Stabilizer Assemblies

    How To... Replace the Stabilizer Assemblies Tools Required: Phillips Screwdriver, 17mm Socket Wrench, 17mm Open End Wrench, 4X4 Block of Wood Estimated Repair Time: 30 Minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3.

  • Page 48: Replace The Transport Wheels

    How To... Replace the Transport Wheels Tools Required: 5mm Allen Wrench, 4X4 Block of Wood, Blue Loctite Estimated Repair Time: 30 Minutes 1. Turn the cross-trainer power switch OFF. 2. Unplug the line cord from the wall outlet. 3. Carefully lift either the front or rear end of the cross-trainer. 4.

  • Page 49: Wiring Diagram

    Electrical Wiring Diagram...

  • Page 50: Glossary

    Levelers Adjustable supports located under the cross-trainer 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. Loctite® A compound of the Henkel Loctite Corporation used to lock and seal components.

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