mogurf21 LifeFitness X1 5 Troubleshooting

X1-5, X3-0 and X3-5 Cross-Trainers

Customer Support ServicesSERVICE MANUAL


INTRODUCTION

This service manual is applicable to X1-5, X3-0 and X3-5 Cross-Trainers. Informationin this manual represents typical configuration and may differ slightly from actual equipment.The Service Manual provides recommendations for safe and efficient approaches to problemsituations. This manual consists of:

Section I TROUBLESHOOTING

Section II DIAGNOSTICS

Section III “How to....”

If an operating problem should arise, turn to the TROUBLESHOOTING GUIDES and attempt toisolate what is causing the malfunction. The GUIDES are suggestions to the most probablecause.

Refer to the appropriate "How To..." which covers step-by-step procedures for the replacementor adjustment of parts. Use of basic hand tools is all that is required to perform most serviceprocedures. If special service tools are required, then “Special Tools Required“ will be listed inthe title page.

FAX or call Life Fitness Customer Support Services, Monday through Friday, 8:00 AM to 5:00PM Central Standard Time. To better assist you in a more efficient and expedient manner,please have the following information ready for the Customer Service Technician as follows:

1. Equipment model number2. Serial number3. Symptom of the problem4. Part name and number to order

If you have any questions or comments please phone, mail, or fax Life Fitness at:

LIFE FITNESS COMPANY - CUSTOMER SUPPORT SERVICES10601 Belmont Avenue, Franklin Park, IL 60131; USATelephone: 847-451-0036, Toll Free: 800-351-3737, FAX: 847-288-3702

Section IVMISCELLANEOUS

ii


SPECIAL SERVICE TOOL REQUIREMENTS

Unless otherwise specified, only basic hand tools are required to perform service proceduresoutlined in this section. Some of these standard tools should consist of: Philips and Straight-Blade Screw Drivers, Torx Set, Pliers, Rubber Mallet, Pry Bar, Snap Ring Pliers (internal andexternal), Standard and Metric; Allen Wrenches, Socket Sets, and Hand Wrenches.

Specialized tools will be listed after the sub-heading Special Service Tools: , which appearsbelow the Service Procedure Heading at the top of the page. If no specialized tools arerequired, then the title would read: Special Service Tools: NONE , which means that standardhand tools should be employed to provide service to the product.

Specialized tools must be used to ensure safe and effective service procedures. Improvisationor attempts to use any other tool could result in unnecessary damage to the equipment orpersonal injury.

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TABLE OF CONTENTS

SECTION I TROUBLESHOOTING GUIDESGRINDING, RUBBING, KNOCKING NOISES WHEN UNDER LOAD .............................................2DRIVE BELT SLIPPING ............................................................................................................ .........2UPPER ARMS FEEL LOOSE.......................................................................................................... ...2PEDAL ARMS FEEL LOOSE .......................................................................................................... ...2NO LOAD DURING OPERATION ............................................................................................................2NO LEDS DISPLAYED ON CONSOLE......................................................................................................3NO RPM..............................................................................................................................................3UNIT ROCKS DURING OPERATION ........................................................................................................3NOTES .................................................................................................................................................4

SECTION II HOW TO…REPLACECONSOLE.......................................................................................................................................... 2

CONSOLE CIRCUIT BOARD.......................................................................................................... .. 3

USER ARMS...................................................................................................................... ................ 4

MONO-COLUMN................................................................................................................... ............ 5

PEDAL ARMS OR BUSHINGS ............................................................. ..................................... ....... 6

LOWER LINK OR BUSHINGS ......................................................................................................... . 7

CRANKARM LINK OR BUSHINGS............................................................................................... ........... 8

CRANKARMS...................................................................................................................... ... ........... 9

UNIT SHROUDS................................................................................................................... .............10

CRANK SHAFT BEARINGS........................................................................................................... ... 12

DRIVE BELT..................................................................................................................... ................. 15

IDLER BRACKET .................................................................................................................. ............16

MAGNETIC BRAKE ASSEMBLY............................................................................................................... 17

REED SWITCH .................................................................................................................... ..............19

BRAKE MOTOR .................................................................................................................... ............20

PEDALS......................................................................................................................... .................... 21

LEVELERS....................................................................................................................... .................. 22

HANDLEBAR GRIPS................................................................................................................ ......... 23

WATER BOTTLE HOLDER............................................................................................................ ... 24

SECTION III MISCELLANEOUSMODEL ID AND S/N ............................................................................................................... ........... 2

PREVENTIVE MAINTENANCE TIPS ..........................................................................................................3

NOTES ................................................................................................................................................4.

SECTION II DIAGNOSTICS

X1-5 & X3-0 DIAGNOSTICS.......................................................................................2X3-5 DIAGNOSTICS..................................................................................................9

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Note

1


SECTION I

TROUBLESHOOTINGGUIDES

2


Malfunction Probable Cause Corrective ActionCrank arm assembly is loose Remove the side shrouds and check

that the crank arm bolt is not loose. Ifloose, re-tighten

Check for worn bushings in at eitherend of the pedal arm. If necessary,replace the bushings.

Pedal arm end play.

Remove the caps at the ends of thepedal arms and check for loose bolts.If necessary, tighten.

Spring (wave) washer damaged orMissing.

Replace as necessary.

Grinding, rubbing, knocking noiseswhen under load.

Crank shaft wobbles Crankshaft bearings worn. See “How To… Replace Crank Shaft Bearings”in Section 3 of the Service Manual.

If belt is worn (frayed), replace.Drive Belt slipping. Worn belt or belt tension is notcorrectly set.

Check that the idler bracket is notloose. If so, re-tension the beltusing the J-Bolt, and then re-tightenthe idler bracket.

Remove the cap that covers thebolt, and check to see if it’s loose.If necessary re-tighten.

Upper Arms feel loose. Mounting bolts could be loose or thespring washer could be worn.

Remove the upper arms andinspect the spring washer. If wornor damaged, replace.

Remove the caps from the top andbottom of the crank arm link, andthen check that the upper and lowermounting bolts are not loose. Ifnecessary, re-tighten.

Pedal arms feel loose. Inspect the crank arm link, whichconnects between the pedal arm And lower link.

If bolts are secure, check thecondition of the bushings. If worn,replace.

Faulty magnetic brake assembly. ReplaceNo load during operation.

Brake cable disconnected. Remove the right shroud andinspect the condition of the brakecable. If excessively worn, replace.If the cable is disconnect, thenreconnect.

3


Malfunction Probable Cause Corrective ActionDisconnected console cable. Remove the console mounting

screws, and then lift the console upjust enough to inspect that the cableis connected to the back of theconsole. If not, re-connect.

Bad main cable to console. Check the condition of the maincable, then check for continuity. Ifno continuity, replace the cable.

No LEDs displayed on console.

Bad power adapter. Replace power adapter.

Bad cable connection to the back ofthe console.

Verify that the cable is properlyconnected to the back if theconsole.

No RPM. Unit shuts off one minuteinto program.

Faulty reed switch or magnet missingon pulley.

Inspect reed switch for damage,and replace if necessary. Makesure it is properly connected. Makesure it is within range of themagnetic in the pulley. Make surethe magnet in the pulley is notmissing.

Unit not stable or level. Adjust levelers as necessary. Thereare four levelers and they are alladjustable.

Unit rocks during operation.

Pedals loose. Inspect that the pedals are notloose. If they are, then the mountingscrews are loose. If so, re-tightenthe four mounting screws, which arelocated under the pedal.

Fail Message Motor runs continuously for 30seconds or more.

Check tension cables.

Bad motor, replace as necessary.

4


Notes


SECTION II

DIAGNOSTICS


To enter diagnostics on an X1-5 or X3-0; Press and hold the Start and Scroll keys whilepowering up the unit as shown in Fig. 1. All LED’s should light up as shown in Fig. 2

Press the Enter key to advance to the next diagnostic state.

Fig. 1 Fig. 2

Entry into diagnostics - X1-5 and X3-0


Metric/English Default and software version - X1-5 and X3-0

Fig. 1

In this state the dot matrix window will display either a “K” for km/metric or an “M” for mile/English as shown in Fig. 1. This setting can be changed by a switch on the rear of the console. The current software version is also displayed in the upper right display window. The two digits displayed should match the last two digits of the software version shown on the IC label. Press the Enter key or wait 5 seconds to advance to the next diagnostic state.


Walking LED Test - X1-5 and X3-0

Fig. 1

In this test the LED’s in the dot matrix window will illuminate line by line.In addition the upper right window will display numeric digits starting with0 and counting up to 9. The lower right window will display the same numbers in reverse order ( from 9 to 0).

Press the Enter key to advance to the next diagnostic state.


RPM, HR and keypad Test - X1-5 and X3-0

In this test the display will show RPM in the upper right window and Heart Rate in thelower right window as shown in Fig. 1. A keypad teat can also be done in this diagnostic state.

Pressing the Start key will display a number 1 in the dot matrix window as shown in Fig. 2.

Fig.1

Fig. 2


RPM, HR and keypad Test - X1-5 and X3-0 - continued

Fig. 3

Pressing the Up Arrow key will display the number 2 in the dot matrix windowas shown in Fig. 3.

Fig. 4

Pressing the Down Arrow key will display the number 3 in the dot matrix windowas shown in Fig. 4.


RPM, HR and keypad Test - X1-5 and X3-0 - continued

Fig. 5

Pressing the Enter key will display the number 4 in the dot matrix windowas shown in Fig. 5

Fig. 6

Pressing the Scroll key will display the number 5 in the dot matrix windowas shown in Fig. 6. Upon completion of this test the display will automaticallyadvance to the final diagnostic state.


Level or resistance Test - X1-5 and X3-0

The upper right window will display resistance levels. The display will start at Level 1 and increase up to 16 and then decrease back down to Level 1. Servo motor changes should be observed throughout this test.

Press the Enter key to exit diagnostics.


Entry into diagnostics - X3-5

ENTERING DIAGNOSTICS MODE

Diagnostics mode can only be entered from Idle mode.

Diagnostics mode can be entered by pressing the Pause/Clear button twice and then pressingthe Cool Down button. The time window for the three button presses is 2 seconds.If this button sequence is not completed within 2 seconds, the monitor returns to Idle mode.

Upon entering Diagnostics mode, the monitor will beep three timesand enter Diagnostic State #1

TOGGLING THROUGH DIAGNOSTIC STATES

While in Diagnostics mode, pressing the Enter button will advance the monitor forward toThe next Diagnostic State.

Once the last State has been reached, advancing the monitor forward via the Enter buttonwill exit the Diagnostic mode and the monitor will enter Idle mode.

DIAGNOSTIC STATE #1, SOFTWARE VERSION NUMBER

The Calories indicator LED will light to show the monitor in Diagnostic State #1.

Diagnostics State #1 will show the software version number in the display of the message center.

DIAGNOSTIC STATE #2, KEYPAD TEST MODE

The following is to be displayed with a key press of the associated button and an audible beep will occur with each key press. All LED’s will be off until the keypad buttons are pressed.

BUTTON DISPLAY

Time “1111111111111111”

Time “2222222222222222”

My Workouts “3333333333333333”

Quick Start “4444444444444444”

Workout Profile “5555555555555555”

Level (in the center) “6666666666666666”

Level (in the center) “7777777777777777”

Clear/Pause “8888888888888888”

Cool Down “9999999999999999”

Level (on the EZ pod) “AAAAAAAAAAAAAAAA”

Level (on the EZ pod) “BBBBBBBBBBBBBBBB”

CT Reverse “CCCCCCCCCCCCCCCC”

CT Aerobics “DDDDDDDDDDDDDDDD”

Enter This will advance the monitor the nextdiagnostic state #3.


Diagnostics - X3-5 - continued

DIAGNOSTIC STATE #3, DISPLAY TEST MODE

The LEDs will toggle between the two bit patterns shown below. See figure 1 and figure 2. The adjacent LEDs in the 14 segment display should not light together. The singleLED’s should light individually. The rows of the 10X14 brickyard display should light individually.

DIAGNOSTIC STATE#4, MAGNET POSITION

The Cool Down LED is lit.

The center 3 digits of the message center digits will show the Level setting from 1 to 20.

The left hand 4 digits of the message center will show a number from 1 to 256 (assuming an 8 bit A/D converter). The number displayed is the desired numerical equivalent for the

location of the magnets from the microprocessor.

The right hand 3 digits of the message center will show a number from 1 to 256. The number displayed is the actual numerical equivalent of the location of the magnets from the Analog to Digital converter or microprocessor.

Pressing the Up Arrow button will activate the motor and move the magnets as to increase Resistance. (Rapid Advance applies) The center display will show the resistance setting, The other 2 displays will show the associated desired and actual position of the magnets.

Pressing the Down Arrow will activate the motor and motor and move the magnets as to decrease resistance. (Rapid Advance applies) The center display will show the resistancesetting, the other 2 displays will show the associated desired and actual position of the magnets.

Figure 1 Figure 2



DIAGNOSTIC STATE #5, A/D TEST

This state displays a number indicating the current motor position and the number that the system used to set that position. The Distance LED is lit.

DIAGNOSTIC STATE #6, SPEED READING TEST

This state displays the signal readings received at the SPU input. The Speed LED will lit and the current RPM reading will be displayed.

DIAGNOSTIC STATE #7, HEART RATE TEST

This state displays the signal readings received by the heart rate receiver input connection.The heart rate LED will flash with each pulse received.

DIAGNOSTIC STATE #8, EEPROM TEST & EE VERSION

This state displays the EEPROM version number. If the Eeprom is not present or fails to function correctly the display shows “EEPROM ERROR”. The Heart Rate % LED will be lit.

DIAGNISTIC STATE #9, RUN TIME

This state displays the total accumulated Time used of the machine.

The left hand 4 digits will show accumulated hours up to 9999 and the right 2 digits of the display will show accumulated minutes up to 59.

Run Time is defined as the amount of time the monitor detects a SPU signal.The Cal / Hour LED is lit.

DIAGNOSTIC STATE #10, DISPLAY TEST

All of the monitor LEDs will be on.

DIAGNOSTIC STATE #11, PHOTO SHOOT MODE

This State places the monitor displays in a “frozen” state simulating a users workout.



USER MENU

The User menu is defined as a user programming state in which the followingParameters can be read and/or programmed;

Prog. State Setting Range Default Description

#1 Pause Time 1-99 5 min. Number of Minutes a work out is Paused.

#2 Sleep Time 0-99 5 Number of minutes before Sleep mode isentered.

0 is defined as no Sleep mode.

#3 Hold Time 1 – 99 10 seconds Number of seconds the current display isheld before automatic enter/advance

#4 Units Eng./Metric Eng. Sets units as English or Metric

#5 Software Displays current software revision.

ENTERING USER MENU

The User Menu can only be entered from Idle mode.

The User Menu can be entered by pressing the Pause/Clear button twice and then pressing the Enter button. The time window for the three button presses is 2 seconds. If this button sequence is not completed within 2 seconds, the monitor returns to Idle mode.

Upon entering the User Menu, the monitor will beep three times, display “USER MENU”(center justified) on the message center for 2 seconds and then enter User Menu, programming state #1.

TOGGLING THROUGH USER MENU STATES

While in the User Menu, pressing the Enter button will advance themonitor forward to the next programming state.

While in the User Menu, pressing the CT Reverse button willadvance the monitor backwards to the previous programming state.

All programmed values are “automatically” saved when Enter is pressed.

If Enter is not pressed after a value has been programmed while the monitor is in any User MenuState, the monitor will accept the displayed value and toggle to the next state after 30 seconds.

If Enter has not been pressed while the monitor is in User Menu program state #4,the monitor will return to Idle mode after 30 seconds.



Once the last User Menu programming state has been reached, advancing the monitor forward via the Enter button will exit the User Menu and the monitor will return to Idle mode.

PROGRAMMING STATE #1, PAUSE TIME

See section 6.1.1 for definition of Pause Time.

See section 4.9 for Default Pause Time.

The message center display will show “PAUSE = XX” with the R eadout center justified within the display.

Pressing either Level or Mode Up button will increment the Pause Time.

Pressing either Level or Mode Down button will decrement the Pause time.

PROGRAMMING STATE #2, SLEEP TIME

This state programs the monitor for the amount of time it will stayin Idle mode before toggling to Sleep mode.

See section 4.9 for Default Sleep Time.

The message center display will show “SLEEP = XXX” with thereadout center justified within the display.

Pressing either Le vel or Mode Up button will increment the SleepTime.

Pressing either Level or Mode Down button will decrement the Sleep Time.

PROGRAMMING STATE #3, HOLD TIME

This state programs the monitor for the amount of time it will holdthe current display before the system times out, accepts the userentry, and advances to the next step.

See section 4.9 for Default settings and range .

The display will show “HOLD = XX”. Where XX is the time persection 4.9 or as the user last entered.

Pressing the Level Up button will increment the Button Time-out.

Pressing the Level Down button will decrement the Button Time-out.



PROGRAMMING STATE #4, ENGLISH/METRIC CONVERSION

This state allows the user to choose between English or metric asthe measurement system for the monitor.

See section 4.9 for Default setting.

The display will show “UNITS = ENG” if English.

The display will show “UNITS = MET” if Metric.

Pressing either the Level/Mode( ) or Level/Mode( ) buttons willtoggle the monitor from English to Metric or Metric to English.

PROGRAMMING STATE #5, SOFTWARE VERSION

Programming State #5 will show the microprocessor softwareversion number in the center numeric display as “X.XX”.

RETURNING TO DEFAULT VALUES

Pressing the Clear/Pause button for more than 2 seconds while themonitor is in User Menu programming states 1, 2 or 3 will returnthe displayed value to its respective default value.

MY WORKOUT

My Workout is a custom programmed profile that can be used by the user.

My Workout is used to store statistics for up to 4 different users.

My Workout is used to program workout profile configurations for up to 4profiles. One profile per user.

My Workout is used to program the names for up to 4 different users.

USER STATISTICS

The My Workout Mode will store the statistics for accumulated Time, accumulatedCalories and accumulated Distance for up to 4 users.

Display Definition

HOURS=XXXX Hours of accumulated workout time

MINUTES=XX Minutes combined with hours is totalaccumulated workout time.

CALORIES=XXXXX Accumulated Cal.

DISTANCE=XXXXX Accumulated Dist.

PROGRAMMABLE PARAMETERS

Operating parameters can be programmed for up to 4 users.

Programmed parameter Definition

Name Name of the user, 16 characters, centerjustified

Profile Workout Profile

Time Time duration of workout

Weight Weight of user

Age Age of user



THR or Level THR for Heart rate profiles, Resistance Levelfor other profiles.

NAME, PROGRAMMING

Up to 4 user names can be programmed.

User selects their name by pressing the My Workout button.

The default display before programming by the user is; MYWORKOUT 1 through MY WORKOUT 4.

User enters editing mode for name or workout by pressing and holding the My Workout key for 2 seconds after the user has selected the user. The message center then shows and scrolls the following message “ PRESS ENTER TO EDIT NAME - PRESS MY WORKOUT TO EDIT WORKOUT”

If the user presses the Enter button to edit name then the message center will showthe user their name or MY WORKOUT X with the first letter flashing.

The user uses the arrow keys to toggle through the alphanumeric characters for the letter that is flashing. Pressing the Up button scrolls forward and pressing the Down button Scrolls backwards through the alphanumeric characters. Key rapid advance applies.

When the user has selected the character to be programmed, pressing the Enter key accepts the letter and toggles the display to the next letter.

The user can press the Pause/Clear button at any time while programming a name to erase the currently flashing letter and edit the previous letter.

Pressing the My Workout button at any time while programming a name will save the the displayed name and the console will toggle to editing workout mode. The message center will show “NAME SAVED” center justified, for 3 seconds.SAVED” center justified, for 3 seconds.



If the user presses the Pause/Clear button and holds it for 2 seconds while in the Name programming mode, then the user’s name will not be saved and the monitor will return to Idle mode.

The characters that can be programmed are the alphabet(capitalized), numerics from 0-9, a blank space and a dash.

The order of the characters is to be alphabet, numbers, space, dash.If the user scrolls through all characters and reaches the end of the character list, the character list will continue scrolling from the beginning.

If there are no key presses within 30 seconds, the monitor will exit programming modeand return to Idle mode. No name will be saved and the message center will display the previously saved name or the default display the next time this mode is entered.

WORKOUT, PROGRAMMING

If the user presses My Workout while the message center isdisplaying “PRESS ENTER TO EDIT NAME – PRESS MYWORKOUT TO EDIT WORKOUT” The message center will thendisplay “PRESS ENTER TO EDIT WORKOUT – PRESS MYWORKOUT TO ACCESS STATISTICS”.

The message center will display “SELECT A WORKOUT”. The user will select a workout via the Workout Profile button or will toggle through the profiles using the arrow buttons. Pressing enter will accept the profile.

The user will be prompted for data just as if the user had selected aprofile. (See section 6.1.6 and 4.14.2)

Upon acceptance of data by the last press of the Enter button the message center will display “WORKOUT SAVED” center justified, for 3 seconds.

The monitor will then return to Idle Mode.

If there are no key presses within 30 seconds, the monitor will exitprogramming mode and return to Idle mode. No workout will besaved and the message center will display the previously savedworkout or the default display the next time this mode is entered.



STATISTICS, DISPLAY

If the user presses the My Workout button when the messagecenter is displaying “PRESS ENTER TO EDIT WORKOUT –PRESS MY WORKOUT TO ACCESS STATISTICS” the monitorwill show the statistics for the user chosen.

The display will toggle to the first statistic to be displayed, whichis to be hours of accumulated Time.

Pressing the My Workout button will advance the message centerto the next statistics which is accumulated minutes. Minutescombined with hours is the total accumulated workout time.

Pressing the My Workout button will toggle the message center tothe next statistics which is accumulated Calories.

Pressing the My Workout button will toggle the message center tothe next statistic which is accumulated Distance.

Pressing the My workout button will exit the statistics displaymode and return the monitor to Idle mode.

If the user presses and holds the Pause/Clear button for 2 secondswhile and statistic is being displayed then the statistic beingdisplayed will be cleared.

If there are no key presses within 30 seconds, the monitor will exitstatistics display mode and return to Idle mode.

1


SECTION III

How To... SERVICE AND REPAIR GUIDES

2

Mono-Column

ConsoleScrews(4)

Console

CableConnector


How To... Replace Console

Special Service Tools: NONE

1. Remove four screws from the back of the console.

2. Raise the console just enough to disconnect the Cable connector, and then remove the console.

3. Install new console in reverse order.

3

Console BackScrews(8)

PCBScrews(4)

PowerCircuitBoard

Console Front


How To... Replace the Console Circuit Board


1. Remove the console assembly. See“How To…” in this section.

2. Remove eight screws from the Console back and separate it From the console front.

3. Disconnect the cable.

4. Remove four screws from the power Circuit board and lift out the PCB.

5. Installation of the PCB and console Assembly is the reverse order.

4

Cap

Nut

Cap Washer

Cap

Bolt

CapWasher

Right Arm

SpringWasher Washer

Cap

Bolt

LockWasher

Washer

Console

X1-5 Cross-Trainers

How To... Replace the User Arms


1. Remove the console assembly. See “How To…” in this section.

2. Remove the hardware as illustrated from the top of the left and right arms and then At the bottom where they connect with the pedal arms.

3. Remove the arms and discard.

4. Install new arms in reverse order.

Note: A torque of 32 lb-ft is used for standard bolts for attaching links together and to the Machine, connecting upright to base frame.

Nut

Bolt

Right Arm

SpringWasher Washer

Cap

Bolt

LockWasher

Washer

Console

X3-0 and X3-5 Cross-Trainers

How To... Replace the User Arms


1. Remove the clevis covers where the user arm and pedal lever attach to each other.

2. Remove the hardware as illustrated from the top of the left and right arms and then At the bottom where they connect with the pedal arms.

3. Remove the arms and discard.

4. Install new arms in reverse order.

Note: A torque of 32 lb-ft is used for standard bolts for attaching links together and to the Machine, connecting upright to base frame.

5

Cap(4)

Bolt(4)

Cap(4)Washer

Cap(4)

Nut(4)

CoverPlateScrew

CoverPlate

CableConnectors

Cap(4)Washer

CableConnector

Cover

CoverScrew

CoverScrew

CoverPlateScrew

X1-5 Cross-Trainers

How To... Replace the Console Mast



2. Remove left and right arms. See “How To…” in this section.

3. Remove the cover from the top of the mono-column.

4. Remove the cover at the bottom of the mono-column between the support plates, and disconnect the cableconnector.

5. Remove caps, bolts, and nuts (as illustrated), and then lift-out the mono-column from the frame.

6. Pull out the cable from the mono-column, and then discard the mono-column.

7. Install new mono-column in reverse order.

Note: A torque of 32 lb-ft is used for standard bolts for attaching links together and to the machine, connectingupright to base frame.

Bolt(4)

Nut(4)

CableConnectors

CableConnector

Cover

CoverScrew

CoverScrew

X3-0 and X3-5 Cross-Trainers

How To... Replace the Console Mast



2. Remove left and right arms. See “How To…” in this section.

3. Remove the cover from the top of the console mast.

4. Remove the right and left console mast covers at the bottom of the console mast anddisconnect the cableconnector.

5. Remove bolts, and nuts (as illustrated), and then lift-out the mono-column from the frame.

6. Pull out the cable from the mono-column, and then discard the mono-column.

7. Install new mono-column in reverse order.


6

PedalArm, RT

Shaft(2)

RT PedalHousing

Bushings(4)

Retaining Ring(4)

Washer(4)

SpringWasher(2)

Cap Washer(4)

Cap(4)

Bolt(2)

Nut(2)

Note: Quantitiesindicated for theRT Pedal Arm, are the same for theLT Pedal Arm.

Same aseplodedview

Note: Cap is groovedfor easy removalwith screwdriver

X1-5 Cross-Trainers

How To... Replace the Pedal Arms or Bushings


Removal of either pedal arm is the same. Use the illustration to aid in removal and re-assembly.


PedalArm, RT

Shaft(2)

RT PedalHousing

Bushings(4)

Retaining Ring(4)

Washer(4)

SpringWasher(2)

Bolt(2)

Nut(2)

Note: Quantitiesindicated for theRT Pedal Arm, are the same for theLT Pedal Arm.

Same aseplodedview

X3-0 AND x3-5 Cross-Trainers

How To... Replace the Pedal Arms or Bushings


Removal of either pedal arm is the same. Use the illustration to aid in removal and re-assembly.


Clevis covers (on the X3-0 and X3-5 models only) must be removed from either end of the pedal arms before proceeding.

7

RetainingRing

SpringWasher

Washer

Bushing

Cap

Washer

Lock Washer

Bolt

Cap

CapWashers

Bolt Nut

Cap

LowerLink, RT

MountingShaft

CrankarmLink


How To... Replace Lower Link or Bushings


1. At the crankarm link, remove the caps ( on the X1-5 model) or the clevis covers ( on the X3-0 and X3-5 models)

2. Remove the bolt, cap washers(2 found on the X1-5 only), and nut securing the lower link.

3. Lower the end of the lower link to the floor.

4. At the pedal end, remove the cap, bolt, washer, and lock washer.

5. Pull the lower link off its mounting shaft.(Note: The X1-5 model has a spring washer, washer, and retaining ring

6. If necessary, drive-out the bushing in the lower link and drive in new ones.

7. Install new lower link in reverse order.


To expose the mounting bolt and nut.

Between the lower link and frame.

8

Bolt

Lock Washer

FlatWasher

Crank ArmLink

Right Lower Arm

Right Pedal Arm

CapWashers

NutEndCap

Locknut

Cap

EndCap

Bolt

EndCap

SpringWasher

Bushing

Washer

RetainingRing

Shaft

Bushing

RetainingRing

Washer

CapWasher

Bolt

Essential, LF Sport, and Bally Cross-Trainers

How To... Replace Crank arm Link or Bushings


1. Remove the end caps on the X1-5or the clevis covers on the X3-0X3-5. Next remove the nuts And bolts securing the crank Arm link to the lower link arm. Rest the lower link arm on theFloor and place a cloth coverOver it to protect it from Getting scratched.

2. Remove the pedal armfrom the top of the crankArm link by removing theend cap or clevis covers, and Then remove the bolt and nut. Rest the pedal arm against the lowerarm, which is covered witha cloth to protect it fromgetting scratched.

3. Remove the crankarm linkfrom the crankarm shaft byremoving the end cap, andthen remove the bolt, lockwasher, and flat washer.

4. Remove the snap rings andwashers. Note the springwasher position, which isnext to the bushing andlocated on the inner side ofthe crankarm link oradjacent to the pedal arm.

5. Remove the shaft and ifnecessary the bushings.Discard worn bushings andshaft.

6. Install bushings in reverseorder using the illustrationto aid in re-assembly.

Note: A torque of 32 lb-ft isused for standard bolts forattaching links together and tothe machine, connecting upright to base frame.

Note: Cap washers and End Caps are present on the X1-5 model only. The X3-0 and X3-5 models have clevis covers instead of cap washers and end caps.

9

Users right Disc

Users left Disc

DiscScrews(8)

DiscScrews(8)

Retainer

RetainerScrews(2)

Bolt

Locknut

Key

Crank arm


How To... Replace the Crank arms


Note: The following procedure covers bothCrank arms. However, if only one crank armrequires replacement, then only remove whatis necessary for that side.

1. Remove the side shrouds. See “HowTo…” in this section.

2. Remove the side discs from each side ofthe pulley retainers. Eight screws hold oneach disc.

3. Remove the retainers by removing two screwssecuring it to the crank arm.

4. Remove the crank arm by removing the boltand nut securing the crank arm to thecrankshaft. Then remove the crank arm andkey from the crankshaft.

5. Install new crank arm and torque theCrank arm bolt to 25 lb-ft.

10

EndCap

Bolt

Locknut

Bolt

Lock Washer

FlatWasher

Crank ArmLink

Right Lower Arm

Right Pedal Arm

CapWashers

NutCap

Bolt

Cap

EndCap

CapWashers

EndCap


How To... Replace Side Shrouds


1. Remove the lower armsfrom the bottom of theCrank arms by removing theend caps or clevis covers, and and then the bolts and nuts. Rest the lower arms on the floor, And then place a cloth over Them to protect them from Getting scratched.

2. Remove the pedal armsfrom the top of theCrank arms by removing theend capsor clevis covers, and Then remove the bolts and Nuts. Rest the pedal arms Against the lower arms which areCovered with a cloth to protect iThem from getting scratched.

3. Remove the crank arm linksfrom the crank arm shaftsbyremoving the caps, andthen remove the bolts, lockwashers, and flat washers.

Note: Cap washers and End Caps are present on the X1-5 model only. The X3-0 and X3-5 models have clevis covers instead of cap washers and end caps.

11

Left Shroud

Right Shroud

Shroud Screws(6)

No Screw

No Screw

No Screw

Screws(9)


How To... Replace Side Shrouds - Continued


4. From the left side shroud, remove nine screws.

5. From the right side shroud, remove six screws.

6. Separate the shrouds and remove them from the unit.

7. Install new shrouds in reverse order.

8. Reinstall crank arms, lower link arms and pedal arms in reverse order.


12

Left Disc

Right Disc

DiscScrews(8)

DiscScrews(8)

Left Retainer

RetainerScrews(2)

Bolt

Locknut

Key

Crank arm


How To... Replace Crank Shaft Bearings

Special Service Tools: Bearing Service Tool Kit – Part Number: Bearing Tool Kit

1. Remove the side shrouds. See “How To…”in this section.

2. Remove the side discs from each side ofthe pulley retainers. Eight screws hold oneach disc.

3. Remove the retainers by removing two screwssecuring it to the crank arm.

4. Remove the crank arm by removing the boltand nut securing the crank arm to thecrankshaft. Then remove the crank arm andkey from the crankshaft.

13

Pulley& Crankshaft

RetainingRings(2)

J-BoltBelt TensioningBracket Bolts

Index Mark


How To... Replace Crank Shaft Bearings - Continued

Special Service Tools: Bearing Service Tool Kit – Part Number: Bearing ToolKit

5. Place an index mark below the idlerbracket so that the belt can be broughtback to its original tension upon re-assembly.

6. Loosen three bolts securing the idlerbracket.

7. Loosen the J-Bolt to slacken the beltenough to slip it off the pulley.

8. On the right side of the frame, remove two snaprings from the crankshaft.

9. From the left side of the frame, pull the pulley andcrankshaft out from the bearings.

14

Bearing Shoulder(Both Sides)

Bearings(Both Sides)

Steel Punchor Brass Drift

CT Frame

Alternatepunchside-to-side

BearingSpacer

Puller Hub

Spacer

Hex Nut

Thread Rod

Bearings

PRESSING IN BEARINGS


How To... Replace Crank Shaft Bearings - Continued

Special Service Tools: Bearing Service Tool Kit – Part Number: Bearing ToolKit

10. Using a brass drift or steel punch, tap out thebearings from the frame. Tap on the inner orouter bearing races from side-to-side and fromtop-to-bottom.

IMPORTANT: DO NOT strike against the insidesurface of the frame, which is the bearing surface.

NOTE: DO NOT REUSE THE BEARINGS.

11. Install new bearings using the “BearingToolKit.”Seat the bearings against the bearing shouldersinside the frame.

12. Install the crankshaft and pulley assembly backinto the bearings.

13. Tension the drive belt from 140-150 lbs.

14. Install the remaining components in reverseorder.

Note: Proper belt tension is critical to avoid beltslippage. After performing any procedure thatrequires the drive belt to be loosened or removed, itis critical that the operation of the cross-trainer betested at low and high RPMs as well as through eachlevel of resistance to ensure the belt is not slipping.

15

Spacers

Nut/Washer

Bolts

Nuts

Left Side Platew/Idler Bracket,and J-Bolt

Electro-MagneticBrake

DriveBelt

Left PlateAllen Screw(2)

IndexMark


How To... Replace Drive Belt


1. Remove the both sideshrouds. See “How To…” inthis section.

2. Place an index mark belowthe idler bracket so that thebelt can be brought back toits original tension upon re-assembly.

3. Loosen the three Allenscrews securing the idlerbracket.

4. Loosen the J-Bolt.

5. Remove the nut and washerfrom the magnetic brakeaxle.

6. Remove two bolts from theleft side plate.

7. Remove two Allen bolts from the left side plate.

8. Remove the left side plate with the idler bracket and J-Bolt attached.

9. Remove the belt off the pulley, and then discard.

10. Install new belt in reverse order. Tension the drive belt from 140-150 lbs.

Note: Proper belt tension is critical to avoid belt slippage. After performing any procedure that requires the drive beltto be loosened or removed, it is critical that the operation of the cross-trainer be tested at low and high RPMs aswell as through each level of resistance to ensure the belt is not slipping.

16

J-Bolt

J-BoltRetainingRing

Lockwasher(3)

AllenScrew(3)

Spacer(3)

Idler Bracket

IndexMark


How To... Replace the Idler Bracket


1. The idler bracket is locatedon the left side of the unit. Toaccess, first remove thecrankarm link. See “HowTo…Remove Shrouds” inthis section.

2. Remove nine screwssecuring the left side shroud,and remove the shroud.

3. Place an index mark belowthe idler bracket so that thebelt can be brought back toits original tension uponinstalling a new bracket.

4. Loosen the J-Bolt, and thenremove the J-Bolt retainingring, and remove the J-Boltfrom the bracket.

5. Remove the three Allenscrews, lock washers, andspacers, which secures theidler bracket to the leftsupport, and remove thebracket.

6. Install new idler bracket, andre-use hardware and J-Bolt.


Note: Proper belt tension is critical to avoid belt slippage. After performing any procedure that requires the drive beltto be loosened or removed, it is critical that the operation of the cross-trainer be tested at low and high RPMs aswell as through each level of resistance to ensure the belt is not slipping.

17

BrakeCable Retainer, RT

Disc, RT

MotorMagneticBrake Assy

Disc, RT

Retainer, RT

BrakeCable

MagneticBrake Assy

Nut/Washer

Idler Bracket

Idler BracketBolt/Lockwasher/Spacer(3)


How To... Replace Magnetic Brake Assembly


1. Remove both sideshrouds. See “How To…”in this section.

2. Remove the right discfrom the crankarmretainer by removing eightscrews from the disc.

3. Remove the retainer fromthe crankarm by removingtwo screws.

4. Disconnect the brakecable from the magneticbrake and motor.

5. Remove the nut andwasher from the magneticbrake axle bolt on the leftside.

6. Loosen the idler bracket bolts and theJ-Bolt to slacken the belt.

7. Loosen four Allen screws secured atthe bottom of the magnetic sideplates.

8. Loosen the long mounting bolts,which secures both side plates. Thenpull the left plate out enough to allowthe drive belt to clear past themagnetic pulley.

9. Remove the four Allen screws fromthe bottom of the side plates, andremove the magnetic brakeassembly.

10. Install a new magnetic brake inreverse order. The left side plate willhave to be removed or loosenedenough to re-install the belt.

18

BrakeCable


SlideBlock

Cable

SlideBlockMark

BrakeMarks


How To... Replace Magnetic Brake Assembly - Continued


11. Apply power to the unit, whichwill automatically set unit at level1.

12. Using the cable adjuster, set themark on the slide block so that itis positioned between the twomarks on the magnetic brake.Check to see that the brake isworking properly, and thensecure lock nut on cable.


Note: Proper belt tension is critical toavoid belt slippage. After performingany procedure that requires the drivebelt to be loosened or removed, it iscritical that the operation of thecross-trainer be tested at low andhigh RPMs as well as through eachlevel of resistance to ensure the beltis not slipping.

19

AllenScrew

ReedSwitch


How To... Replace the Reed Switch


Note: Access the reed switch from the rightside of the unit.

1. Remove the right crankarm link. See“How To…” in this section.

2. Remove the right side shroud. See “HowTo…” in this section.

3. Disconnect the reed switch cableconnector.

4. Remove the Allen screw securing thereed switch to the frame, and removethe reed switch.

Note: The right side disc was removed forclarity.

5. Install a new reed switch in the reverseorder.

6. Set the gap between the magnet and the reed switch to 0.12 - 0.20 inch.

20

Screw(2)& Washer(2)

Motor

BrakeCable

BrakeCable


SlideBlock

Cable

SlideBlockMark

BrakeMarks


How To... Replace the Brake Motor


Note: Access the brake motor from the rightside of the unit.

1. Remove the right crankarm link. See “HowTo…” in this section.

2. Remove the right side shroud. See “HowTo…” in this section.

3. Remove the right disc. See “How To…Replace Magnetic Brake Assembly” in thissection.

4. Disconnect the brake cable from themagnetic brake, and then from the motor.

5. Remove two screws securing the motorfrom its mounting bracket, and then lower itout.

6. Install new motor in the reverse order.

7. Apply power to the unit, whichwill automatically set unit at level1.

8. Using the cable adjuster, set themark on the slide block so that itis positioned between the twomarks on the magnetic brake.Check to see that the brake isworking properly, and thensecure lock nut on cable.

21

Left Pedal

PedalScrews(4)& Washers(4)

RightPedal

PedalScrews(4)& Washers(4)


How To... Replace the Pedals


1. Each pedal is secured by screws(4)and washers(4), which are locatedunder pedal. Remove these screwsand washers, and then lift off the pedal.

2. Install new pedals in reverse order.

22

Leveler(4)

Jam Nut(4)

Front Stabilizer Bar


How To... Replace the Levelers


There are four levelers, one at each end of the frontand rear stabilizer bars. It is important that beforeusing the unit, that all four levelers are adjusted sothat it is both level and stable before operating.

Each leveler has a threaded bolt that can be turnedin or out of the stabilizer bar to achieve a level andstable unit. A jam nut on the thread bolt is use tosecure the position of the leveler.

To make adjustments, loosen the jam nut, and thenturn the leveler in or out accordingly. Do this foreach leveler as required.

When adjustments are complete, tighten the jamnut against the stabilizer to secure the position ofthe leveler.

23

Grips


How To... Replace the Handlebar Grips


1. Pull-off the old grips. It may be necessary to cut-offthe grips.

2. Push-on the new grips. It may be necessary to use arubber mallet to install.

24

Water Bottle

Water BottleHolder

HolderScrews(2)


How To... Replace the Water Bottle Holder


1. Remove the water bottle from thewater bottle holder.

2. Remove the mounting screws(2)securing the water bottle holder tothe frame.

3. Install new water bottle holder.

1


SECTION III

MISCELLANEOUS

2


MODEL IDENTIFICATION and SERIAL NUMBER LOCATION

S/N and ID Numbers

3


PREVENTIVE MAINTENANCE TIPS

Preventive Maintenance Schedule

WEEKLY MONTHLY BI-ANNUALLY ANNUALLY

DisplayConsole

Clean Inspect - -

MountingBolts

- - Inspect -

Frame Clean - - Inspect

PlasticCovers

Clean Inspect - -

4


Notes:

© 2000 Life Fitness, a division of Brunswick Corporation. All rights reserved. Life Fitness, Lifecycle, and Lifepulse are registered trademarks and Heart,Rate Zone Training and RELY ON IT are trademarks of Brunswick Corporation. Polar is a registered trademark of Polar Electronic.

Any use of these trademarks without the express written consent of Life Fitness or the corresponding companies is forbidden.

Part No. #7937101

August 2005

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mogurf21 LifeFitness X1 5 Troubleshooting