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Life Fitness Lifecycle 3500 Series Service Manual

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See also: Operating Manual , Manual
Lifecycle 3500, 4500, 5500 Series
Exercise Bikes
Customer Support Services
SERVICE MANUAL

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Summary of Contents for Life Fitness Lifecycle 3500 Series

  • Page 1 Lifecycle 3500, 4500, 5500 Series Exercise Bikes Customer Support Services SERVICE MANUAL...
  • Page 2 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 Fitness Customer Support Services any Monday through Friday from 8:00 AM to 6:00 PM ( C.S.T.).
  • Page 3 ©1997 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. 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.

  • Page 4: Table Of Contents

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes TABLE OF CONTENTS INTRODUCTION (How to use this Service Manual) TABLE OF CONTENTS SECTION I TROUBLESHOOTING GUIDES PAGE No Power ........................1 Display Console Initializes, But Does Not Stay On............2 Lights Flicker Or Fade In And Out/Erratic Display............3 Flashing Prompt Remains On ..................
  • Page 5 Check wire harnesses for damage Defective Display Console Switch or replace Display Console Defective Alternator Control Switch or replace Alternator Control Board Board Defective Alternator Switch or replace Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 6: Troubleshooting Guide

    Alternator Control Board, Alternator and but doesn’t stay on Battery Check wire harnesses for damage Defective Display Console Switch Display Console Defective Alternator Control Switch Alternator Control Board Board Defective Alternator Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 7: Lights Flicker Or Fade In And Out/Erratic Display

    Alternator Control Board, Alternator and Battery Damaged wire harness Check wire harness for damage Defective Alternator Control Switch or replace Alternator Control Board Board Defective Aternator Switch or replace Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 8: Flashing Prompt Remains On

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

  • Page 9: Loads At Start Of A Program

    Check wire harness for damage Alternator output low Check Alternator Output Defective Display Console Switch Display Consoles Defective Alternator Control Switch Alternator Control Board Board Defective Alternator Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 10: Loads In Middle Of A Program

    Switch Alternator Control Board Board Alternator output low Check Alternator output. Should be 9-10V. Red probe on output, Black probe on ground. Pedal and press Start. Defective Alternator Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 11: Keys Do Not Respond (Start Button Not Included)

    Keys do not respond May be in cold area Massage keypad with fingertips to warm Defective Display Console See diagnostics on keypad test Overlay Defective Display Switch or replace Display Console For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 12: Exercise Bike Is Making A Loud Noise

    Damaged crank bearings Replace worn crank bearings Loose or damaged chain Replace chain Alternator/flywheel assembly Replace Alternator/flywheel assembly damaged or worn Worn freewheel Gear Replace freewheel gear and pulley bearings For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 13: Level Changes During Program

    Switch Alternator Control Board Board Alternator output low Check Alternator output. Should be 9-10V. Red probe on output, Black probe on ground. Pedal and press Start. Defective Alternator Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 14: Difficult To Pedal: Display Is Off

    Loosen drive belt tension. There should be 1/4” (6mm) maximum play Defective freewheel gear If user can not pedal backwards, replace the freewheel gear Defective crank bearings Replace crank bearings For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 15: Too Easy To Pedal

    Switch Alternator Control Board Board Alternator has incorrect voltage Check Alternator output. Should be output 9-10V. Red probe on output, Black probe on ground. Pedal and press Start. Defective Alternator Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 16: Tension Stays The Same

    Switch Alternator Control Board Board Alternator has incorrect voltage Check Alternator output. Should be output 9-10V. Red probe on output, Black probe on ground. Pedal and press Start. Defective Alternator Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...

  • Page 17: Will Not Pedal Forward

    Chain has frozen link(s) Replace chain. Left crank nut too tight Loosen crank nut by 1/16 turn. Crank bearings worn or rusted 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 Exercise Bikes...

  • Page 18: Flashing Prompt Goes Off When Start Button Is Released

    Check Alternator output. Should be Alternator has incorrect voltage output 9-10V. Red probe on output, Black probe on ground. Pedal and press Start. Defective Alternator q Switch Alternator For Assistance Call: Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737...
  • Page 19 Lifecyle 3500, 4500, 5500 Series Exercise Bikes NOTES:...
  • Page 20 Lifecyle 3500, 4500, 5500 Series Exercise Bikes NOTES:...

  • Page 21: Lifecycle 3500, 4500, 5500 Series Exercise Bikes

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes DIAGNOSTICS TESTS Press, and continue to hold, the ‘5’ key on the keypad and then press ‘START’ 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.
  • Page 22 Lifecycle 3500, 4500, 5500 Series Exercise Bikes DIAGNOSTICS TESTS (Continued) DIAGNOSTICS STATE 1 This test indicates that all keys on the Display are responding properly. Pressing keys in this state verifies and displays a value in each 7 segment display. q Press PROGRAM SELECT key to display 'A' q Press 1 key to display '1' q Press 2 key to display ‘2’...
  • Page 23 Continued Lifecycle 3500, 4500, 5500 Series Exercise Bikes DIAGNOSTICS TESTS ( Continued ) DIAGNOSTICS STATE 3 This test indicates the state of the Software Version and Jumper Options. ELAPSED TIME WINDOW Upon entry the system will beep and begin displaying the current pedal rpm blank in the 3 digits of the pedal rpm window.
  • Page 24 Lifecycle 3500, 4500, 5500 Series Exercise Bikes NOTES:...

  • Page 25: How To

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE ALTERNATOR Tools Required: Grease pencil, 5/16" wrench, 1/4" wrench, 1/2" wrench, 3/4" wrenches (2) Step 1 Remove the HOUSING (See “How To...”). Step 2 Remove the two POSITIVE RED WIRES from their POSTS on the ALTERNATOR. With a 1/4" wrench, remove the two NUTS securing the BLACK FIELD WIRE and the WHITE WIRE.

  • Page 26: Alternator

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE ALTERNATOR CONTROL BOARD / RESISTOR Tools Required: 3/8" wrench, 1/4" wrench, 5/16" wrench, pliers, scissors Step 1 Remove the HOUSING (See “How To. . .”). Step 2 Remove the DISPLAY CONSOLE (See “How To. . .”). Step 3 Locate DISPLAY WIRE HARNESS slot in FRAME, gently pull out the DISPLAY WIRE HARNESS from the FRAME.

  • Page 27: Alternator Belt

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE ALTERNATOR BELT Tools Required: 1/2" wrench, two 3/4" wrenches Step 1 Remove the HOUSING (See “How To. . .”). Step 2 With a 1/2" wrench, loosen the ALTERNATOR ADJUSTMENT BOLT. Step 3 With two 3/4"...

  • Page 28: Battery

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE BATTERY Tools Required: None Step 1 Remove the BATTERY DOOR on the rear of the DISPLAY CONSOLE by pushing down on the two tabs at the top of the DOOR. Step 2 Gently guide the BATTERY WIRES out so that you can disconnect the worn BATTERY.

  • Page 29: Chain

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE CHAIN Tools Required: Standard screwdriver, needle-nose pliers Step 1 Remove the HOUSING (See “How To...”). Step 2 With a standard screwdriver, pry apart the MASTER LINK RETAINER CLIP. Then, with a needle nose pliers, remove the MASTER LINK RETAINING CLIP, the MASTER LINK and the MASTER LINK PLATE from the worn CHAIN.

  • Page 30: Crank Bearing / Nut Assemblies

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE THE EXISTING CRANK BEARING/NUT ASSEMBLIES Tools Required: Special crank arm wrench required (available from Life Fitness), torque wrench (30 FT. LB. with 32mm open end), punch, standard screwdriver, hex key wrench set, clean rag WARNING: IF THE INFORMATION IN THESE INSTRUCTIONS ARE NOT FOLLOWED EXACTLY, THE EXERCISE BIKE MAY BE SERIOUSLY DAMAGED AND MAY VOID YOUR WARRANTY.

  • Page 31: Crank Bearing / Nut Assemblies

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...INSTALL THE NEW CRANK BEARING/NUT ASSEMBLIES Step 10 Slide the right CRANK BEARING/NUT ASSEMBLY over the CRANK ARM. Using the 32mm crank arm wrench, install the BEARING CRANK NUT ASSEMBLY until it seats against the SPROCKET.

  • Page 32: Footstraps

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE FOOTSTRAP Tools Required: None Step 1 Grasp the outside of the worn STRAP and pull AWAY and DOWN from the knob on the PEDAL. Step 2 Grasp the inside of the 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.

  • Page 33: Handlebar Assembly/Display Console

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE HANDLEBAR ASSEMBLY/DISPLAY CONSOLE Tools Required: 3/8" wrench, 1/8" hex key wrench Step 1 Raise the COLLAR from the HOUSING and tape it to the HANDLEBAR POST. With a 3/8" wrench, remove the two HANDLEBAR BOLTS and the CARRIAGE BOLT and NUT at the base of the HANDLEBAR POST.

  • Page 34: Handlebar Assembly/Display Console

    Lifecycle 5500HB Series Exercise Bikes How To...REMOVE AND REPLACE THE HANDLEBAR ASSEMBLY /DISPLAY CONSOLE Tools Required: Socket set, 1/8” hex key wrench Step 1 Raise the COLLAR from the HOUSING and tape it to the HANDLEBAR POST. Step 2 Disconnect the 8-PIN CONNECTORS of the wire harnesses located at the base of the HANDLEBAR POST.
  • Page 35 Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE FREEWHEEL ASSEMBLY Tools Required: E-Ring tool, light hammer, needle-nose pliers, two standard screwdrivers, 1/2" wrench, two 3/4" wrenches Step 1 Remove the HOUSING (See “How To...”). Step 2 Remove the CHAIN (See “How To...”).

  • Page 36: Housing

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE HOUSING Tools Required: 5/8" Open end wrench, Phillips screwdriver, plastic tube Step 1 Raise the COLLAR from the HOUSING and tape it to the HANDLEBAR POST. Step 2 If you intend to remove only one side of the HOUSING, begin by removing the right PEDAL (sprocket side).

  • Page 37: Remove/Replace The Pedals

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE PEDALS Tools Required: 5/8" open-end wrench Step 1 To remove the LEFT PEDAL (small hole-side of HOUSING) place a 5/8" open-end wrench on the PEDAL BOLT. Turn the wrench clockwise and remove the PEDAL. Step 2 To remove the RIGHT PEDAL (sprocket side) place a 5/8"...

  • Page 38: Seat/Seat Post

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE SEAT/SEAT POST Tools Required: 9/16" Wrench Step 1 Pull the SEAT PIN out from the SEAT POST and bike frame. Slide the SEAT POST up and out from the frame of bike.

  • Page 39: Adjustable Foot Cap

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes How To...REMOVE AND REPLACE THE ADJUSTABLE FOOT CAP Tools Required: Rubber mallet Step 1 Turn the Lifecycle trainer on to it’s side. Step 2 Remove the worn FOOT CAP from the STABILIZER TUBE by pulling and twisting on the FOOT CAP in either direction.
  • Page 40 Lifecycle 3500, 4500, 5500 Series Exercise Bikes NOTES:...
  • Page 41 Lifecycle 3500, 4500, 5500 Series Exercise Bikes NOTES:...

  • Page 42: Parts Identification

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes PARTS IDENTIFICATION Item Description Part Numbers Common To Part Numbers Common To Models 3500, 4500, 5500 Model 5500HB SEATPOST W/SEAT ASSY AK18-00183-0000 AK18-00183-0000 SEATPOST ASSY: PURCHASED AK17-00062-0000 AK18-00176-0000 CONSOLE-ASSY AK17-00076-0001 AK17-00165-0001 PARTS-BAG ASSY AK17-00078-0000 AK17-00160-0000 OVERLAY/BEZEL...
  • Page 43 Lifecycle 3500, 4500, 5500 Series Exercise Bikes PARTS IDENTIFICATION...

  • Page 44: Lifecycle 3500, 4500, 5500 Series Exercise Bikes

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes NOTES:...

  • Page 45: Model Identification And Serial Number Location

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION...

  • Page 46: Preventive Maintenance Tips

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes PREVENTIVE MAINTENANCE To keep the coasting action of the Lifecycle trainer smooth, clean and lubricate the FREEWHEEL GEAR bi-annually with a light lubricating oil. Watch for excessive wear on the Teeth of the SPROCKET. Keep the ALTERNATOR BELT tight.
  • Page 47 Lifecycle 3500, 4500, 5500 Series Exercise Bikes PREVENTIVE MAINTENANCE ( Continued )

  • Page 48: Wiring Block Diagrams

    Lifecycle 3500, 4500, 5500 Series Exercise Bikes WIRING BLOCK DIAGRAM...

  • Page 49: Communicating By Fax

    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 CUSTOMER SUPPORT SERVICES PARTS ORDER SALE ( IF BOTH PLEASE INDICATE ) PRODUCT TROUBLESHOOTING WARRANTY NAME: CUSTOMER NO: DATE: PHONE: FAX: CONTACT NAME: METHOD OF SHIPMENT: 1 DAY 2 DAY GROUND PARTS ORDER FORM ITEM NO. PART NUMBER DESCRIPTION QUANTITY PRODUCT TROUBLESHOOTING PRODUCT NAME: SERIAL NO.
  • Page 51 Lifecycle 3500, 4500, 5500 Series Exercise Bikes NOTES:...
  • Page 52 Lifecycle 3500, 4500, 5500 Series Exercise Bikes NOTES:...

This manual is also suitable for:

Lifecycle 4500 seriesLifecycle 5500 series

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