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

Customer Support Services

SERVICE MANUAL

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

INTRODUCTION
This service manual is applicable to X1-5, X3-0 and X3-5 Cross-Trainers. Information in this manual represents typical configuration and may differ slightly from actual equipment. The Service Manual provides recommendations for safe and efficient approaches to problem situations. This manual consists of: Section I TROUBLESHOOTING Section II DIAGNOSTICS Section III How to.... Section IV MISCELLANEOUS

If an operating problem should arise, turn to the TROUBLESHOOTING GUIDES and attempt to isolate what is causing the malfunction. The GUIDES are suggestions to the most probable cause. Refer to the appropriate "How To..." which covers step-by-step procedures for the replacement or adjustment of parts. Use of basic hand tools is all that is required to perform most service procedures. If special service tools are required, then Special Tools Required will be listed in the title page. FAX or call Life Fitness Customer Support Services, Monday through Friday, 8:00 AM to 5:00 PM 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 number 2. Serial number 3. Symptom of the problem 4. 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 SERVICES 10601 Belmont Avenue, Franklin Park, IL 60131; USA Telephone: 847-451-0036, Toll Free: 800-351-3737, FAX: 847-288-3702

X1-5, X3-0 and X3-5 Cross-Trainers SPECIAL SERVICE TOOL REQUIREMENTS Unless otherwise specified, only basic hand tools are required to perform service procedures outlined in this section. Some of these standard tools should consist of: Philips and StraightBlade Screw Drivers, Torx Set, Pliers, Rubber Mallet, Pry Bar, Snap Ring Pliers (internal and external), Standard and Metric; Allen Wrenches, Socket Sets, and Hand Wrenches. Specialized tools will be listed after the sub-heading Special Service Tools: , which appears below the Service Procedure Heading at the top of the page. If no specialized tools are required, then the title would read:Special Service Tools: NONE , which means that standard hand tools should be employed to provide service to the product. Specialized tools must be used to ensure safe and effective service procedures. Improvisation or attempts to use any other tool could result in unnecessary damage to the equipment or personal injury.

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

TABLE OF CONTENTS

SECTION I TROUBLESHOOTING GUIDES

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

SECTION II DIAGNOSTICS X1-5 & X3-0 DIAGNOSTICS.......................................................................................2 X3-5 DIAGNOSTICS..................................................................................................9 SECTION II HOW TOREPLACE
CONSOLE.......................................................................................................................................... 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 MISCELLANEOUS

MODEL ID AND S/N ............................................................................................................... ........... 2 PREVENTIVE MAINTENANCE TIPS ..........................................................................................................3 NOTES ................................................................................................................................................ 4

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

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

SECTION I

TROUBLESHOOTING GUIDES

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

Malfunction
Grinding, rubbing, knocking noises when under load.

Probable Cause
Crank arm assembly is loose

Corrective Action
Remove the side shrouds and check that the crank arm bolt is not loose. If loose, re-tighten Check for worn bushings in at either end of the pedal arm. If necessary, replace the bushings. Remove the caps at the ends of the pedal arms and check for loose bolts. If necessary, tighten.

Pedal arm end play.

Spring (wave) washer damaged or Missing. Crank shaft wobbles

Replace as necessary.

Crankshaft bearings worn. See How To Replace Crank Shaft Bearings in Section 3 of the Service Manual. If belt is worn (frayed), replace. Check that the idler bracket is not loose. If so, re-tension the belt using the J-Bolt, and then re-tighten the idler bracket.

Drive Belt slipping.

Worn belt or belt tension is not correctly set.

Upper Arms feel loose.

Mounting bolts could be loose or the spring washer could be worn.

Remove the cap that covers the bolt, and check to see if its loose. If necessary re-tighten. Remove the upper arms and inspect the spring washer. If worn or damaged, replace.

Pedal arms feel loose.

Inspect the crank arm link, which connects between the pedal arm And lower link.

Remove the caps from the top and bottom of the crank arm link, and then check that the upper and lower mounting bolts are not loose. If necessary, re-tighten. If bolts are secure, check the condition of the bushings. If worn, replace.

No load during operation.

Faulty magnetic brake assembly. Brake cable disconnected.

Replace Remove the right shroud and inspect the condition of the brake cable. If excessively worn, replace. If the cable is disconnect, then reconnect.

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

Malfunction
No LEDs displayed on console.

Probable Cause
Disconnected console cable.

Corrective Action
Remove the console mounting screws, and then lift the console up just enough to inspect that the cable is connected to the back of the console. If not, re-connect. Check the condition of the main cable, then check for continuity. If no continuity, replace the cable. Replace power adapter.

Bad main cable to console.

Bad power adapter. No RPM. Unit shuts off one minute into program.

Bad cable connection to the back of Verify that the cable is properly the console. connected to the back if the console. Faulty reed switch or magnet missing Inspect reed switch for damage, on pulley. and replace if necessary. Make sure it is properly connected. Make sure it is within range of the magnetic in the pulley. Make sure the magnet in the pulley is not missing.

Unit rocks during operation.

Unit not stable or level.

Adjust levelers as necessary. There are four levelers and they are all adjustable. Inspect that the pedals are not loose. If they are, then the mounting screws are loose. If so, re-tighten the four mounting screws, which are located under the pedal. Check tension cables. Bad motor, replace as necessary.

Pedals loose.

Fail Message

Motor runs continuously for 30 seconds or more.

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

Notes

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

SECTION II

DIAGNOSTICS

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

Entry into diagnostics - X1-5 and X3-0

Fig. 1

Fig. 2

To enter diagnostics on an X1-5 or X3-0; Press and hold the Start and Scroll keys while powering up the unit as shown in Fig. 1. All LEDs should light up as shown in Fig. 2 Press the Enter key to advance to the next diagnostic state.

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

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.

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

Walking LED Test - X1-5 and X3-0

Fig. 1

In this test the LEDs in the dot matrix window will illuminate line by line. In addition the upper right window will display numeric digits starting with 0 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.

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

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

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

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

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

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 window as shown in Fig. 3.

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

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

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 window as shown in Fig. 5

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

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

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.

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

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 pressing the 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 times and enter Diagnostic State #1 TOGGLING THROUGH DIAGNOSTIC STATES While in Diagnostics mode, pressing the Enter button will advance the monitor forward to The next Diagnostic State. Once the last State has been reached, advancing the monitor forward via the Enter button will 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 LEDs will be off until the keypad buttons are pressed.
BUTTON Time Time My Workouts Quick Start Workout Profile Level Level (in the center) (in the center) Clear/Pause Cool Down Level Level (on the EZ pod) (on the EZ pod) CT Reverse CT Aerobics Enter DISPLAY 1111111111111111 2222222222222222 3333333333333333 4444444444444444 5555555555555555 6666666666666666 7777777777777777 8888888888888888 9999999999999999 AAAAAAAAAAAAAAAA BBBBBBBBBBBBBBBB CCCCCCCCCCCCCCCC DDDDDDDDDDDDDDDD This will advance the monitor the next diagnostic state #3.

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

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 singleLEDs should light individually. The rows of the 10X14 brickyard display should light individually.

Figure 1

Figure 2

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 resistance setting, the other 2 displays will show the associated desired and actual position of the magnets.

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

Diagnostics - X3-5 - continued

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.

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

Diagnostics - X3-5 - continued

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

Prog. State #1 #2

Setting Pause Time Sleep Time

Range 1-99 0-99

Default 5 min. 5

Description Number of Minutes a work out is Paused. Number of minutes before Sleep mode is entered. 0 is defined as no Sleep mode.

#3 #4 #5

Hold Time Units Software

1 99 Eng./Metric

10 seconds Eng.

Number of seconds the current display is held before automatic enter/advance Sets units as English or Metric 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 the monitor forward to the next programming state. While in the User Menu, pressing the CT Reverse button will advance 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 Menu State, 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.

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

Diagnostics - X3-5 - continued

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 stay in Idle mode before toggling to Sleep mode. See section 4.9 for Default Sleep Time. The message center display will show SLEEP = XXX with the readout 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 hold the current display before the system times out, accepts the user entry, 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 per section 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.

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

Diagnostics - X3-5 - continued

PROGRAMMING STATE #4, ENGLISH/METRIC CONVERSION This state allows the user to choose between English or metric as the 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 will toggle the monitor from English to Metric or Metric to English. PROGRAMMING STATE #5, SOFTWARE VERSION Programming State #5 will show the microprocessor software version number in the center numeric display as X.XX. RETURNING TO DEFAULT VALUES Pressing the Clear/Pause button for more than 2 seconds while the monitor is in User Menu programming states 1, 2 or 3 will return the 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 4 profiles. 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, accumulated Calories and accumulated Distance for up to 4 users. Display HOURS=XXXX MINUTES=XX CALORIES=XXXXX DISTANCE=XXXXX Definition Hours of accumulated workout time Minutes combined with hours is total accumulated workout time. Accumulated Cal. Accumulated Dist.

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

Diagnostics - X3-5 - continued

PROGRAMMABLE PARAMETERS Operating parameters can be programmed for up to 4 users. Programmed parameter Name Profile Time Weight Age THR or Level Definition Name of the user, 16 characters, center justified Workout Profile Time duration of workout Weight of user Age of user THR for Heart rate profiles, Resistance Level for 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; MY WORKOUT 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 show the 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.

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

Diagnostics - X3-5 - continued

If the user presses the Pause/Clear button and holds it for 2 seconds while in the Name programming mode, then the users 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 mode and 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 is displaying PRESS ENTER TO EDIT NAME PRESS MY WORKOUT TO EDIT WORKOUT The message center will then display PRESS ENTER TO EDIT WORKOUT PRESS MY WORKOUT 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 a profile. (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 exit programming mode and return to Idle mode. No workout will be saved and the message center will display the previously saved workout or the default display the next time this mode is entered.

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

Diagnostics - X3-5 - continued

STATISTICS, DISPLAY If the user presses the My Workout button when the message center is displaying PRESS ENTER TO EDIT WORKOUT PRESS MY WORKOUT TO ACCESS STATISTICS the monitor will show the statistics for the user chosen. The display will toggle to the first statistic to be displayed, which is to be hours of accumulated Time. Pressing the My Workout button will advance the message center to the next statistics which is accumulated minutes. Minutes combined with hours is the total accumulated workout time. Pressing the My Workout button will toggle the message center to the next statistics which is accumulated Calories. Pressing the My Workout button will toggle the message center to the next statistic which is accumulated Distance. Pressing the My workout button will exit the statistics display mode and return the monitor to Idle mode. If the user presses and holds the Pause/Clear button for 2 seconds while and statistic is being displayed then the statistic being displayed will be cleared. If there are no key presses within 30 seconds, the monitor will exit statistics display mode and return to Idle mode.

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

SECTION III

How To... SERVICE AND REPAIR GUIDES

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

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.
Console

Cable Connector MonoColumn Console Screws(4)

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

How To... Replace the Console Circuit Board

Special Service Tools: NONE

1. Remove the console assembly. SeeHow 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.
Console Front

Power Circuit Board

PCB Screws(4)

Console Back Screws(8)

X1-5 Cross-Trainers

How To... Replace the User Arms

Special Service Tools: NONE

Console

Right Arm

Lock Washer Bolt Cap Washer

Spring Washer

Washer

Cap Washer Bolt Cap

Cap

Nut Cap Washer

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.

X3-0 and X3-5 Cross-Trainers

How To... Replace the User Arms

Special Service Tools: NONE

Console

Right Arm

Lock Washer Bolt Cap Washer

Spring Washer

Washer

Bolt

Nut

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.

X1-5 Cross-Trainers

How To... Replace the Console Mast

Special Service Tools: NONE

Cover Screw Cable Connector

Cover

Cover Screw Cover Plate Screw Cover Plate Screw Cover Plate Cap(4)

Cable Connectors Bolt(4) Cap(4) Cap(4) Washer

1. Remove the console assembly. See How To in this section. 2. Remove left and right arms. See How To in this section. 3. Remove the cover from the top of the mono-column.

Cap(4) Nut(4) Washer

4. Remove the cover at the bottom of the mono-column between the support plates, and disconnect the cable connector. 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, connecting upright to base frame.

X3-0 and X3-5 Cross-Trainers

How To... Replace the Console Mast

Special Service Tools: NONE

Cover Screw Cable Connector

Cover

Cover Screw

Nut(4) Cable Connectors Bolt(4)

1. Remove the console assembly. See How To in this section. 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 cable connector. 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. 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.

X1-5 Cross-Trainers

How To... Replace the Pedal Arms or Bushings

Special Service Tools: NONE

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

Note: Quantities indicated for the RT Pedal Arm, are the same for the LT Pedal Arm. Same as eploded view

Nut(2) RT Pedal Housing Pedal Arm, RT Bushings(4) Washer(4) Bolt(2) Cap(4) Shaft(2) Retaining Ring(4) Cap Washer(4)

Spring Washer(2)

Note: Cap is grooved for easy removal with screwdriver

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.

X3-0 AND x3-5 Cross-Trainers

How To... Replace the Pedal Arms or Bushings

Special Service Tools: NONE

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.

Note: Quantities indicated for the RT Pedal Arm, are the same for the LT Pedal Arm. Same as eploded view

Nut(2) RT Pedal Housing Pedal Arm, RT Bushings(4) Washer(4) Bolt(2) Shaft(2) Retaining Ring(4)

Spring Washer(2)

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.

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

How To... Replace Lower Link or Bushings

Special Service Tools: NONE

Cap Washers Bolt

Cap

Crankarm Link

Mounting Shaft Retaining Ring Washer Spring Washer

Nut

Lower Link, RT

Cap Lock Washer Bolt

Bushing Washer

Cap
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) To expose the mounting bolt and nut. 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 Between the lower link and frame. 6. If necessary, drive-out the bushing in the lower link and drive in new ones. 7. Install new lower link 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.

Essential, LF Sport, and Bally Cross-Trainers

How To... Replace Crank arm Link or Bushings

Special Service Tools: NONE

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.
1. Remove the end caps on the X1-5 or the clevis covers on the X3-0 X3-5. Next remove the nuts And bolts securing the crank Arm link to the lower link arm. Rest the lower link arm on the Floor and place a cloth cover Over it to protect it from Getting scratched. 2. Remove the pedal arm from the top of the crank Arm link by removing the end cap or clevis covers, and Then remove the bolt and nut. Rest the pedal arm against the lower arm, which is covered with a cloth to protect it from getting scratched. 3. Remove the crankarm link from the crankarm shaft by removing the end cap, and then remove the bolt, lock washer, and flat washer. 4. Remove the snap rings and washers. Note the spring washer position, which is next to the bushing and located on the inner side of the crankarm link or adjacent to the pedal arm. 5. Remove the shaft and if necessary the bushings. Discard worn bushings and shaft. 6. Install bushings in reverse order using the illustration to aid in re-assembly. 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.
End Cap Nut Cap Washers

Right Pedal Arm Right Lower Arm

Bolt

End Cap

Lock Washer Cap Crank Arm Link Locknut Retaining Ring Washer Spring Washer Shaft Bushing Bushing Washer Retaining Ring Flat Washer

Bolt

Cap Washer Bolt End Cap

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

How To... Replace the Crank arms

Special Service Tools: NONE Note: The following procedure covers both Crank arms. However, if only one crank arm requires replacement, then only remove what is necessary for that side. 1. Remove the side shrouds. See How To in this section. 2. Remove the side discs from each side of the pulley retainers. Eight screws hold on each disc.
Users right Disc Disc Screws(8) Users left Disc

Disc Screws(8)

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

Retainer Screws(2) Retainer

4. Remove the crank arm by removing the bolt and nut securing the crank arm to the crankshaft. Then remove the crank arm and key from the crankshaft. 5. Install new crank arm Crank arm bolt to 25 lb-ft. and torque the

Crank arm

Key

Locknut Bolt

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

How To... Replace Side Shrouds

Special Service Tools: NONE

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.
1. Remove the lower arms from the bottom of the Crank arms by removing the end 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 arms from the top of the Crank arms by removing the end capsor clevis covers, and Then remove the bolts and Nuts. Rest the pedal arms Against the lower arms which are Covered with a cloth to protect i Them from getting scratched. 3. Remove the crank arm links from the crank arm shaftsby removing the caps, and then remove the bolts, lock washers, and flat washers.

Right Pedal Arm Right Lower Arm Nut Cap Washers Bolt End Cap

Cap

Lock Washer Cap Crank Arm Link Flat Washer

Bolt

End Cap Locknut Cap Washers End Cap Bolt

10

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

How To... Replace Side Shrouds - Continued

Special Service Tools: NONE

Left Shroud Screws(9)

No Screw

No Screw

No Screw Right Shroud Shroud Screws(6)

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.

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.

11

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

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 of the pulley retainers. Eight screws hold on each disc.
Disc Screws(8) Right Disc

Left Disc

Disc Screws(8)

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

Retainer Screws(2) Left Retainer

4. Remove the crank arm by removing the bolt and nut securing the crank arm to the crankshaft. Then remove the crank arm and key from the crankshaft.

Crank arm

Key

Locknut Bolt

12

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

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 idler bracket so that the belt can be brought back to its original tension upon reassembly. 6. Loosen three bolts securing the idler bracket. 7. Loosen the J-Bolt to slacken the belt enough to slip it off the pulley.

Belt Tensioning Bracket Bolts Index Mark

J-Bolt

Pulley & Crankshaft Retaining Rings(2)

8. On the right side of the frame, remove two snap rings from the crankshaft. 9. From the left side of the frame, pull the pulley and crankshaft out from the bearings.

13

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

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 the bearings from the frame. Tap on the inner or outer bearing races from side-to-side and from top-to-bottom. IMPORTANT: DO NOT strike against the inside surface 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 shoulders inside the frame. 12. Install the crankshaft and pulley assembly back into the bearings. 13. Tension the drive belt from 140-150 lbs. 14. Install the remaining components in reverse order. Note: Proper belt tension is critical to avoid belt slippage. After performing any procedure that requires the drive belt to be loosened or removed, it is critical that the operation of the cross-trainer be tested at low and high RPMs as well as through each level of resistance to ensure the belt is not slipping.
CT Frame

Bearings (Both Sides)

Bearing Shoulder (Both Sides)

Steel Punch or Brass Drift

Thread Rod Hex Nut Spacer Bearing Spacer

Alternate punch side-to-side

Bearings

Puller Hub

PRESSING IN BEARINGS

14

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

How To... Replace Drive Belt

Special Service Tools: NONE 1. Remove the both side shrouds. See How To in this section. 2. Place an index mark below the idler bracket so that the belt can be brought back to its original tension upon reassembly. 3. Loosen the three Allen screws securing the idler bracket. 4. Loosen the J-Bolt. 5. Remove the nut and washer from the magnetic brake axle. 6. Remove two bolts from the left side plate.

Drive Belt Brake Electro-Magnetic Left Side Plate w/Idler Bracket, and J-Bolt Nut/ Washer Spacers Bolts Index Mark Left Plate Allen Screw(2)

Nuts

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 belt to be loosened or removed, it is critical that the operation of the cross-trainer be tested at low and high RPMs as well as through each level of resistance to ensure the belt is not slipping.

15

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

How To... Replace the Idler Bracket

Special Service Tools: NONE 1. The idler bracket is located on the left side of the unit. To access, first remove the crankarm link. See How ToRemove Shrouds in this section. 2. Remove nine screws securing the left side shroud, and remove the shroud. 3. Place an index mark below the idler bracket so that the belt can be brought back to its original tension upon installing a new bracket. 4. Loosen the J-Bolt, and then remove the J-Bolt retaining ring, and remove the J-Bolt from the bracket. 5. Remove the three Allen screws, lock washers, and spacers, which secures the idler bracket to the left support, and remove the bracket. 6. Install new idler bracket, and re-use hardware and J-Bolt. 7. 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 belt to be loosened or removed, it is critical that the operation of the cross-trainer be tested at low and high RPMs as well as through each level of resistance to ensure the belt is not slipping.

Idler Bracket

Spacer(3) Mark Index

Allen Screw(3) J-Bolt Lockwasher(3) J-Bolt Retaining Ring

16

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

How To... Replace Magnetic Brake Assembly

Special Service Tools: NONE 1. Remove both side shrouds. See How To in this section. 2. Remove the right disc from the crankarm retainer by removing eight screws from the disc. 3. Remove the retainer from the crankarm by removing two screws. 4. Disconnect the brake cable from the magnetic brake and motor. 5. Remove the nut and washer from the magnetic brake axle bolt on the left side. 6. Loosen the idler bracket bolts and the J-Bolt to slacken the belt. 7. Loosen four Allen screws secured at the bottom of the magnetic side plates. 8. Loosen the long mounting bolts, which secures both side plates. Then pull the left plate out enough to allow the drive belt to clear past the magnetic pulley. 9. Remove the four Allen screws from the bottom of the side plates, and remove the magnetic brake assembly. 10. Install a new magnetic brake in reverse order. The left side plate will have to be removed or loosened enough to re-install the belt.
Nut/ Washer Idler Bracket Idler Bracket Bolt/Lockwasher/ Spacer(3)

Magnetic Brake Assy

Motor

Brake Cable

Retainer, RT Disc, RT
Disc, RT Retainer, RT

Brake Cable

Magnetic Brake Assy

17

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

How To... Replace Magnetic Brake Assembly - Continued

Special Service Tools: NONE 11. Apply power to the unit, which will automatically set unit at level 1. 12. Using the cable adjuster, set the mark on the slide block so that it is positioned between the two marks on the magnetic brake. Check to see that the brake is working properly, and then secure lock nut on cable. 13. Tension the drive belt from 140150 lbs. Note: Proper belt tension is critical to avoid belt slippage. After performing any procedure that requires the drive belt to be loosened or removed, it is critical that the operation of the cross-trainer be tested at low and high RPMs as well as through each level of resistance to ensure the belt is not slipping.

Magnetic Brake Assy

Motor

Brake Cable

Slide Block Mark

Brake Marks Slide Block

Cable

18

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

How To... Replace the Reed Switch

Special Service Tools: NONE Note: Access the reed switch from the right side of the unit. 1. Remove the right crankarm link. See How To in this section. 2. Remove the right side shroud. See How To in this section. 3. Disconnect the reed switch cable connector. 4. Remove the Allen screw securing the reed switch to the frame, and remove the reed switch. Note: The right side disc was removed for clarity. 5. Install a new reed switch in the reverse order. 6. Set the gap between the magnet and the reed switch to 0.12 - 0.20 inch.

Allen Screw

Reed Switch

19

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

How To... Replace the Brake Motor

Special Service Tools: NONE Note: Access the brake motor from the right side of the unit. 1. Remove the right crankarm link. See How To in this section. 2. Remove the right side shroud. See How To in this section. 3. Remove the right disc. See How To Replace Magnetic Brake Assembly in this section. 4. Disconnect the brake cable from the magnetic brake, and then from the motor. 5. Remove two screws securing the motor from its mounting bracket, and then lower it out. 6. Install new motor in the reverse order. 7. Apply power to the unit, which will automatically set unit at level 1. 8. Using the cable adjuster, set the mark on the slide block so that it is positioned between the two marks on the magnetic brake. Check to see that the brake is working properly, and then secure lock nut on cable.

Screw(2) & Washer(2) Motor Brake Cable

Magnetic Brake Assy

Motor

Brake Cable

Slide Block Mark

Brake Marks Slide Block

Cable

20

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

How To... Replace the Pedals

Special Service Tools: NONE 1. Each pedal is secured by screws(4) and washers(4), which are located under pedal. Remove these screws and washers, and then lift off the pedal. 2. Install new pedals in reverse order.

Left Pedal

Pedal Screws(4) & Washers(4)

Pedal Right

& Washers(4) Screws(4) Pedal

21

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

How To... Replace the Levelers

Special Service Tools: NONE There are four levelers, one at each end of the front and rear stabilizer bars. It is important that before using the unit, that all four levelers are adjusted so that it is both level and stable before operating. Each leveler has a threaded bolt that can be turned in or out of the stabilizer bar to achieve a level and stable unit. A jam nut on the thread bolt is use to secure the position of the leveler. To make adjustments, loosen the jam nut, and then turn the leveler in or out accordingly. Do this for each leveler as required. When adjustments are complete, tighten the jam nut against the stabilizer to secure the position of the leveler.

Front Stabilizer Bar Jam Nut(4)

Leveler(4)

22

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

How To... Replace the Handlebar Grips

Special Service Tools: NONE 1. Pull-off the old grips. It may be necessary to cut-off the grips. 2. Push-on the new grips. It may be necessary to use a rubber mallet to install.

Grips

23

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

How To... Replace the Water Bottle Holder

Special Service Tools: NONE 1. Remove the water bottle from the water bottle holder. 2. Remove the mounting screws(2) securing the water bottle holder to the frame. 3. Install new water bottle holder.

Water Bottle

Holder Screws(2)

Water Bottle Holder

24

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

SECTION III

MISCELLANEOUS

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

MODEL IDENTIFICATION and SERIAL NUMBER LOCATION

S/N and ID Numbers

X1-5, X3-0 and X3-5 Cross-Trainers PREVENTIVE MAINTENANCE TIPS Preventive Maintenance Schedule
WEEKLY Display Console Mounting Bolts Frame Plastic Covers Clean Clean Clean MONTHLY Inspect Inspect BI-ANNUALLY Inspect ANNUALLY Inspect -

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