Treadmill 95T-DOMLX-DOMHX-INTHX-01 - Service - Manual - M051 - 00K65-A003

95T-DOMLX-01
PCST-DOMLX-01
PCST-DOMLX-02
95T-DOMHX-01
PCST-DOMHX-01
PCST-DOMHX-02
95T-INTHX-01
PCST-INTHX-01
PCST-INTHX-02
Customer Support Services
SERVICE MANUAL
95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

Table of Contents
TABLE OF CONTENTS
INTRODUCTION
USING THIS MANUAL ........................................................................... 5
CONTACTING CUSTOMER SUPPORT .......................................................... 7
THEORY OF OPERATION ....................................................................... 9
SERVICE TOOLS ................................................................................11
GLOSSARY ......................................................................................13
TROUBLESHOOTING
NO POWER TO TREADMILL ...................................................................17
NO POWER TO CONSOLE......................................................................17
TREADMILL PAUSES OR RESETS RANDOMLY ................................................18
WORKOUT SUMMARY APPEARS IN THE MIDDLE OF A WORKOUT.........................18
REDUCED MAXIMUM SPEED ...................................................................18
KNOCKING NOISE ..............................................................................19
RUBBING SOUND FROM UNDER THE TREADMILL...........................................19
SQUEAKING NOISE WHEN BELT MOVES .....................................................19
GRINDING NOISE DURING INCLINE...........................................................19
GRINDING NOISE ON FOOTFALL .............................................................19
STRIDING BELT SLIPS..........................................................................19
STRIDING BELT NOT CENTERED OR TRAVELS BEYOND TRACKING LIMITS ..............20
LIFT MOTOR WILL ONLY INCLINE ............................................................20
ABNORMALLY HIGH LIFEPULSE READINGS..................................................20
LIFEPULSE SYSTEM DOES NOT RESPOND OR DISPLAYS INCORRECT READING..........20
CONSOLE DISPLAYS A HEART RATE READING WITHOUT A SIGNAL PRESENT ...........21
NO HEART RATE TRANSMITTER DETECTED.................................................21
HOW TO
HOW TOREPLACE THE CUP HOLDERS .....................................................25
HOW TOREPLACE THE LINE CORD ........................................................26
HOW TOREPLACE THE REAR CONSOLE COVER...........................................27
HOW TOREPLACE THE CONSOLE ASSEMBLY..............................................28
HOW TOREPLACE THE CONSOLE NECK SPACER..........................................29
HOW TOREPLACE THE ACTIVITY ZONE ASSEMBLY ......................................30
HOW TOREPLACE THE INSIDE HANDRAIL COVERS .......................................31
HOW TOREPLACE THE LOWER BRIDGE COVER.......................................... 32
HOW TOREPLACE THE OUTSIDE HANDRAIL COVERS ....................................33
HOW TOREPLACE THE UPPER BRIDGE COVER ...........................................34
HOW TOREPLACE THE HANDRAIL..........................................................35
HOW TOREPLACE THE HEART RATE HAND SENSORS ....................................36
HOW TOREPLACE THE ERGO BAR ASSEMBLY.............................................37
HOW TOREPLACE THE TOP MOTOR SHROUD COVER....................................38
HOW TOREPLACE THE UPRIGHT COVERS.................................................39
HOW TOREPLACE THE UPRIGHTS .........................................................40
HOW TOREPLACE THE MAIN CABLE .......................................................42
HOW TOREPLACE THE BOTTOM MOTOR SHROUD COVER ..............................43
HOW TOREPLACE THE REAR END CAPS ...................................................44
95T-DOMLX-01, 95T-DOMX-01, and 95T-INTHX-01 Treadmills

Table of Contents
TABLE OF CONTENTS CONTINUED

HOW TOREPLACE THE LOWER EXTRUSIONS .............................................45
HOW TOREPLACE THE UPPER EXTRUSION/ANTI-SLIP PAD ASSEMBLIES ..............46
HOW TOREPLACE THE FRONT ROLLER ASSEMBLY.......................................48
HOW TOREPLACE THE DRIVE BELT ........................................................50
HOW TOREPLACE THE IDLER BRACKET ASSEMBLY ......................................52
HOW TOREPLACE THE DRIVE MOTOR .....................................................53
HOW TOREPLACE THE LIFT MOTOR ...................................................... 57
HOW TOREPLACE THE MOTOR CONTROLLER ........................................... 58
HOW TOREPLACE THE ON/OFF SWITCH ................................................. 59
HOW TOREPLACE THE LINE FILTER ...................................................... 60
HOW TOREPLACE THE IEC RECEPTACLE................................................. 61
HOW TOREPLACE THE HOME SWITCH.................................................... 63
HOW TOREPLACE THE REAR ROLLER GUARDS .......................................... 64
HOW TOREPLACE THE REAR ROLLER ASSEMBLY........................................ 65
HOW TOREPLACE THE STRIDING BELT AND DECK ...................................... 66
HOW TOTENSION A STRIDING BELT ..................................................... 70
HOW TOADJUST THE STRIDING BELT TRACKING ...................................... 71
HOW TOREPLACE THE LIFESPRINGS...................................................... 72
HOW TOREPLACE THE STRIDE SENSOR ASSEMBLY ..................................... 73
HOW TOREPLACE THE REAR TOE GUARD................................................ 75
ELECTRONICS
DSP CONTROLLER BOARD ....................................................................79
POWER COMPONENTS SCHEMATIC ......................................................... 82
BLOCK DIAGRAM .............................................................................. 83
INDEX ....................................................................................................87
INTRODUCTION

Introduction
USING THIS MANUAL

This service manual provides safe and efficient step-by-step test and service procedures for
the treadmills. Illustrations are service views that complement the procedures.
Throughout the manual, all messages viewed on the consoles are shown in uppercase letters
and quotation marks. Any keys depressed on the console will appear in uppercase letters.
Descriptions using the words left and right refer to the orientation of a user standing on
the treadmills striding belt, facing the console. Front is the area of unit with the console,
the rear of the treadmill is behind the user.
This manual is comprised of these sections:
Table of contents
Introduction
Troubleshooting
How to service and repair guides
Electronics
Index
When an operating problem occurs, attempt to isolate the cause by referring to the
troubleshooting guides and diagnostic tests. Symptoms are listed in these guides with tests
and probable causes. Once the source of the problem has been identified, refer to the How
To guides for repair procedures. The How To guides are organized by replaceable part
or assembly name. For convenience, each guide lists the tools and estimated time required to
complete the repair.
Before installing a part, read the entire "How To..." section and follow the step-by-step
procedures. This will ensure a safe and efficient installation.
These symbols are occasionally used to highlight information:
Information that will be helpful while performing a procedure.
Information that will prevent damage to the treadmill.
Information that will prevent personal injury or damage to the treadmill.
95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

Introduction

Introduction
CONTACTING CUSTOMER SUPPORT

Life Fitness Customer Support Services can be contacted Monday through Friday from 8:00 am
to 5:00 pm (Central Time).
Life Fitness Customer Support Services
5100 River Road, Schiller Park, IL 60176 (USA)
Telephone: toll-free (800) 351-3737, local (847) 451-0036
Fax: toll-free (800) 216-8893, local (847) 288-3702
www.lifefitness.com
commercialservices@lifefitness.com
Please be prepared to provide this information:
Serial number
Model number
Part name and number
Problem or symptom
Model and serial

number locations

Introduction

Introduction
THEORY OF OPERATION
The treadmill is an electromechanical fitness device that operates on alternating current.
The main components of the treadmill are:
Frame
Striding belt and deck
Display console
Drive motor
DSP Motor controller
Lift (incline) motor
Electronics
Activity Zone
AC power enters the unit through the line cord. This is converted to DC power, which is
necessary to operate the motor controller and various other electrical and mechanical
components. The operator controls all of the treadmills electromechanical components and
makes adjustments to the units speed and incline through the display console. Custom
workout programs are selected through the console as well.
The frame is critical, not only for supporting the users weight, but also for providing a stable
base for the moving components. The striding belt and deck are designed to endure constant
mechanical stress loads. The main motor has a pulley on the end of its shaft, which is
connected by a Poly-V drive belt to the front roller pulley. The striding belt tension is
adjustable by means of tensioning bolts, which are located at the ends of the rear roller.
When turned, these bolts also help center the striding belt. The striding belt is pre-lubricated
which helps minimize wear. The deck is flexible which provides lower impact to the user.
LifeSprings under the deck absorb impact while providing support and stability to the user.
The display console is the control center of the treadmill, where all programming operations
and diagnostic functions are controlled. Selections are made with touch keys. The console
allows the user to choose operational settings; specify workout routines; and input
information such as weight, age, display, language, etc.

Introduction
10

Introduction
SERVICE TOOLS
Unless otherwise specified, these tools are required to perform the service procedures in this
manual:
Screwdrivers (Phillips and flat blade)
Pliers (regular and needle nose)
Rubber mallet
Snap ring pliers (internal and external)
Socket wrenches (English and metric)
Combination, open-end, or box wrenches (English and metric)
Allen wrenches (English and metric)
Mini flashlight
Removable thread locking compound
Cord or twine
2 blocks (e.g., scrap 4 X 4 wood)
Loctite 242
Multimeter
Specialized tools may be required to complete some service procedures safely. Using tools
improperly can result in damage to equipment or personal injury.
11

Introduction
12

Introduction
GLOSSARY
Term
Activity Zone
Anti-slip pad
Bucket
Connector
Cable tie
Console
Deck
DSP
EEPROM
Electromechanical
EPROM
Ergo bar
ESD
Flash memory
Front roller
Heat sink
Home switch
IEC
Integrated circuit
Jumper
km/h
Definition
The remote keypad located on the Ergo bar which allows quick and
easy access to the functions provided on the main console
A rubber strip located on the surface of each side of the frame used
to avoid slipping while mounting or dismounting the treadmill
A software memory area
A device used to join wiring to complete an electrical circuit
A plastic strap used to secure wiring
The electronic component used for making direct input settings and
monitoring the output messages displayed in the digital readout
display (also display console board)
A fibrous particleboard used for the running surface
Digital Signal Processor
Electrically Erasable Programmable Read Only Memory, a rewriteable
memory chip that holds its content without power
Relating to a mechanical device or system that is controlled or
actuated by electricity
Erasable Programmable Read Only Memory, a special type of memory
that retains its contents until exposed to ultraviolet light
The crossbar containing the Lifepulse sensors (from ergonomic)
Electrostatic Discharge, the sudden and momentary electric current
that flows when an excess of electric charge, stored on an electrically
insulated object, finds a path to an object at a different electrical
potential (such as ground)
A form of non-volatile computer memory that can be electrically
erased and reprogrammed
The motor-driven roller that moves the striding belt
An object, usually metal, which lowers the temperature of a heatgenerating component through thermal mass and heat dissipation
The component that senses the treadmills zero-incline position
The common name for a C13 plug/C14 socket combination; from
International Electromechanical Commission, a standards and
conformity assessment body
A small electronic device made of a semiconductor material (also
known as a chip)
An electrical connector used to short circuit two electrical points
Kilometers per hour
table continued
13

Introduction
GLOSSARY CONTINUED
Term
LED
Leveler
Lifepulse
LifeSpring
Lift motor
Loopback test
Drive belt
Main wire harness
MET
Motor controller
mph
Definition
Light Emitting Diode
One of two adjustable supports under the rear of the treadmill, which
level and stabilize the unit by raising or lowering the rear corners
The component that measures heart rate through hand sensors
Elastic devices used for deck suspension
The component that raises and lowers the unit for incline and decline
operations
A diagnostic procedure in which a signal is transmitted and returned
to the sending device after passing through a network or circuit
The component which transmits power from the drive motor to the
front roller
The device which connects circuit boards
Metabolic Equivalent, the ratio of the metabolic rate of the average
person while seated and resting to the metabolic rate of a particular
person while performing a task
Electronic device which regulates the speed of the striding belt
Rear roller guards
Miles per hour

A radio frequency device which monitors a heart rate through signals
received from a chest strap transmitter
Pulse Width Modulation
The free-spinning, adjustable component used to tension and center
the striding belt
Protective components located on each end of the rear roller
rpm
Revolutions per minute
Single-phase AC
Producing, carrying, or powered by one alternating voltage
Static current
Steady flow of electricity
Stop switch
The electrical component used to terminate a workout routine
Stride sensor
The component which detects a users impact on the deck
Striding belt
The moving part of the unit on which a user walks or runs

A device which reads a heart rate signal from a chest strap
transmitter
Producing, carrying, or powered by three equal, alternating voltages
a brand name of fabric hook-and-loop fasteners used for connecting
objects
A circuit board located under the motor shroud used to communicate
input/output signals from the console to the lift and drive motors
Polar receiver
PWM
Rear roller
Telemetry receiver
Three-phase AC
Velcro
Wax/lift board
14
TROUBLESHOOTING
95T-DOMLX-01, 95T-DOMHX-01 and 95T-INTHX-01 Treadmills

Troubleshooting
TROUBLESHOOTING
Tool required: multimeter
Symptom
Probable Cause
Insufficient line voltage at
outlet
Defective Line Cord

No power to
treadmill
Defective line filter
Defective power switch
Insufficient line voltage at

outlet
No power to
console
Defective Line Cord
Defective line filter
Defective power switch
Defective DSP controller

Defective main cable
harness
Corrective Action
Unplug the treadmill from the wall outlet
and measure the line voltage with a
multimeter at the outlet. Switch the
treadmill to an outlet with sufficient line
voltage if necessary.
Inspect line cord for proper seating in wall
outlet and treadmill. Reseat if necessary.
Inspect line cord for damage. Replace line
cord if necessary.
Using a multimeter, check for line voltage
at TP2. If no line voltage is present,
replace the line filter.
Remove the motor cover and turn the
power switch on. Using a multimeter,
check for line voltage at TP1. If no line
voltage is present, replace the power
switch.
Unplug the treadmill from the wall outlet
and measure the line voltage at the outlet
with a multimeter. Switch the treadmill to
an outlet with sufficient line voltage if
necessary.
Inspect line cord for proper seating in wall
outlet and treadmill. Reseat if necessary.
Inspect line cord for damage. Replace line
cord if necessary.
Using a multimeter, check for line voltage
at TP2. If no line voltage is present,
replace the line filter.
Remove the motor cover and turn the
power switch on. Using a multimeter,
check for line voltage at TP1. If no line
voltage is present replace the power
switch.
If the LEDs on the motor controller are not
illuminated, replace the motor controller.
Ensure solid connections at both ends of
the main cable harness. Using a
multimeter, test for point-to-point
continuity on the cable. Replace the main
cable harness if necessary.
17
95T-DOMLX-01, 95TDOMHX-01 and 95T-INTHX-01 Treadmills

Troubleshooting
TROUBLESHOOTING CONTINUED
Symptom
Probable Cause
Treadmill not on a
dedicated line
Treadmill pauses or resets

randomly
Improperly seated power

cord at outlet
Damaged or missing
ground prong on power
cord
Stop switch is false
triggering
Loose connections on
display console
Damaged or shorted main

cable harness
Workout summary appears

in the middle of a workout
Reduced maximum speed
18
Stop switch is false

triggering
Loose main cable
connections at console
Corrective Action
Connect the treadmill to a
dedicated line. See operation
manual for power requirements.
Properly seat the power cord in
the outlet.
Replace the power cord.
Replace the stop switch.
Inspect all cable connections at
the console. Tighten as
necessary.
Ensure solid connections at both
ends of the main cable harness.
Using a multimeter, test for
point-to-point continuity and
point-to-ground continuity on
the main cable harness. Replace
the main cable harness if
necessary.
Replace the stop switch.
Verify that all cable connections

at the console are secure.
Unplug the treadmill from the
wall outlet. Using a multimeter,
Insufficient line voltage at measure the line voltage at the
outlet
outlet. Switch the treadmill to
an outlet with sufficient line
voltage if necessary.
Perform the belt/deck test (see
Worn deck and/or striding the console service manual).
belt
Replace the belt and flip the
deck if necessary (see page 66).
Check the drive motor shaft for
binding or roughness. Replace
Main motor binding
the motor if necessary.
Inspect rollers for binding or
Front or rear roller binding roughness. Replace the front
and/or rear roller if necessary.

Troubleshooting
Symptom
Probable Cause
Treadmill not level
Knocking noise
Faulty front or rear roller

bearings
LifeSprings incorrectly
positioned and/or have
loose mounting hardware
Foreign objects under
treadmill
Rubbing sound from under

the treadmill
Squeaking noise when belt

moves
Grinding noise during

incline
Striding belt not positioned

properly
Worn or damaged main

drive belt
Drive motor pulley and
front roller pulley
misaligned
Obstruction in lift
mechanism
Defective lift motor
Grinding noise on footfall
Excessive friction between

deck and striding belt
Striding belt slips
Incorrect striding belt

tension
Corrective Action
Level the treadmill according
to the instructions in the
operation manual.
Inspect rollers for binding or
roughness. Replace rollers as
necessary.
Reposition or tighten the
LifeSprings and mounting
hardware.
Remove any debris or foreign
objects causing interference.
Reposition the striding belt so
that it is between the belt
guides on both sides of the
treadmill and not resting on
any LifeSpring brackets.
Inspect the main drive belt for
damage or wear. Replace the
main drive belt if necessary.
Align the pulleys as described
in the procedure on page 53.
Remove anything interfering
with the operation of the lift
mechanism.
Replace the lift motor.
Perform the belt/deck test
(see console service manual)
Replace the belt and flip the
deck if necessary (see page
66).
Adjust the striding belt tension
as described on page 70.
19

Troubleshooting
Symptom
Probable Cause
Treadmill not level
Striding belt not within belt
barriers
Striding belt not

centered or
traveling beyond
its tracking limits
Striding belt not tracking

properly
Worn striding belt
Lift motor will only

incline
Abnormally high
Lifepulse readings
Lifepulse system
does not respond
or displays
incorrect reading
DSP controller not receiving

proper incline positioning
information
Electromagnetic interference
from devices such as cell
phones, televisions, or
computers in close proximity
to the treadmill
Level the treadmill according to the

instructions in the Operation manual.
Position the striding belt inside the
belt barriers on both sides of the
frame.
Adjust the tracking of the striding belt
as described on page 71.
Perform the belt/deck test (see
console service manual) Replace the
belt and flip the deck if necessary
(see page 66). The striding belt and
deck should always have new surface
to new surface when a striding belt is
being replaced.
Check cable connections between the
lift motor and the DSP controller.
Replace components as necessary.
Identify the interfering source and
turn it off or increase the distance
between it and the treadmill.
Dirty Lifepulse sensors
Wipe the sensors with a clean, damp

cloth. Verify proper operation using
the Lifepulse test (see Apollo or
Gemini service manual.
Pace over 4.5 mph (7.5

km/h) while attempting to
read heart rate
Slow the pace to less than

4.5 mph (7.5 km/h).
User has an unusual heart

condition or signal
Loose connection between
sensors and console
Faulty Lifepulse sensors
Faulty console board
20
Corrective Action
Have another user grasp the sensors to

compare and verify any unusual
signal.
Verify that the Lifepulse cable
connections at both the hand sensors
and console are secure.
Replace the Lifepulse sensors.
Conduct the Lifepulse test (see
console service manual). Replace the
console board if necessary.

Troubleshooting
Symptom
Probable Cause
Pinched wire harness
Console displays a heart

rate reading without a
signal present
Interference from
electronic devices such as
cell phones, televisions, or
computers in close
proximity to the treadmill.
Electromagnetic
interference from another
telemetry device
Telemetry feature turned
off
Transmitter sensors not

making good contact with
users body
No heart rate transmitter
detected
Transmitter exceeding
usable monitoring range
Faulty connection at
receiver
Faulty transmitter
Faulty receiver
Corrective Action
Inspect the wire harness for
damage. Replace as necessary.
Identify the interfering source

and turn it off or increase the
distance between it and the
treadmill.
Enable the telemetry feature

(see console service manual).
Refer to Operation manual for
the correct placement of the
transmitter on the users body.
Tighten the chest strap and
moisten the sensors to make
better contact between the
transmitter and the users skin.
Stay within 3 feet (1 meter) of
the receiver.
Check the receiver cable to
ensure proper connection.
Replace the receiver as
necessary.
Replace the transmitter.
Replace the receiver.
21

Troubleshooting
22
HOW TO

How To
HOW TO... REPLACE THE CUP HOLDERS

Tool required: No tools required
Estimated time required: 15 minutes
1. Reach under the bridge and disengage
the clip locking the cup holder to the
bridge cover.
2. Lift out the cup holder.
3. Slide the new cup holder down until it
locks into place.
25

How To
HOW TO... REPLACE THE LINE CORD

Tool required: stubby Phillips screwdriver
1. Turn the treadmill
power switch off.
Retaining Bracket
2. Unplug the line cord

from the wall outlet.
3. Lift the front end of
the treadmill
approximately 4 inches
off the floor and place
a block of wood
underneath both sides
to support it.
4. Remove and save the
two screws that secure
the line cord retaining
bracket to the motor
pan.
5. Unplug the defective
line cord.
6. Install the new line
cord, using the screws
removed and saved in
step 4, in reverse
order.
26
Line
Cord

How To
HOW TO REPLACE THE REAR CONSOLE COVER

Tool required: 4mm Allen wrench
1. Remove and save the two Allen
bolts that secure the rear console
cover to the console mounting
bracket.
Rear Console Cover
2. Remove the rear console cover.

3. Install the new rear console cover
using the bolts removed and saved
in step 1.
Rear Console
Cover Screws (2)
27

How To
HOW TO REPLACE THE CONSOLE ASSEMBLY

Tools required: Phillips screwdriver, 4mm Allen wrench
Console Bracket
1. Turn the treadmill power switch

off.
2. Unplug the line cord from the
wall outlet.
Console
Console Mounting
Screws (4)
3. Remove the rear console cover.

See the How To on the
previous page.
Rear
Console
Cover
4. Remove and save the four

Phillips screws that secure the
console assembly to the console
mounting bracket.
5. Disconnect all cables to the
console assembly.
6. Remove the console assembly.
7. Install the new console assembly
in reverse order using the
screws removed and saved in
step 4.
Rear Console
Cover Screws (2)
The replaced console and all associated paperwork must be returned to Life
Fitness.
28

How To
HOW TO REPLACE THE CONSOLE NECK SPACER

1. Turn the treadmill power switch off.
2. Unplug the line cord from the wall
outlet.
Console Bracket
3. Remove the rear console cover. See the

How To. on page 27.
4. Remove the console assembly. See the
How To on page 28.
5. Remove and save the two Allen bolts
that secure the console neck spacer to
the console mounting bracket.
6. Remove the console neck spacer.
7. Install the new console neck spacer in
reverse order using the bolts removed
and saved in step 5.
Neck Spacer
Screws (2)
Console
Neck
Spacer
29

How To
HOW TO REPLACE THE ACTIVITY ZONE ASSEMBLY

Tools required: 4mm Allen wrench, mini flashlight
outlet.
3. Remove the bezel access door located
on the bottom of the lower bridge cover.
4. Remove and save the two bolts that
secure the Activity Zone assembly to the
bridge weldment. (Use the flashlight to
locate the bolts.)
5. Disconnect cable connections to the
Activity Zone.
6. Remove the Activity Zone assembly.
7. Install the new Activity Zone assembly in
reverse order, using the bolts removed
Bezel Access Door

Activity Zone assembly
(as seen from below )
Screws
30

How To
HOW TO REPLACE THE INSIDE HANDRAIL COVERS

Tool required: 4mm Allen wrench
1. Remove and save the five plugs in the
inside handrail covers that conceal the
mounting bolts.
2. Remove and save the five Allen bolts
that secure the inside handrail cover to
the handrail.
3. Remove the cover by tilting it toward
the inside of the unit and then pulling
down.
4. Install the new Inside Handrail Cover in
reverse order, using the bolts removed
Plug (5)
Allen Screw (5)
31

How To
HOW TO REPLACE THE LOWER BRIDGE COVER

1. Turn the treadmill power
switch off.
Bridge Weldment

wall outlet.
3. Remove the cup holders. See
the How To on page 25.
4. Remove the Activity Zone
assembly. See the How
To on page 30.
Upright Bolt Heads

(2 on each side)
5. Remove and save the two

Allen bolts that secure the
lower bridge cover to the
bridge weldment.
6. Remove and save the ten
Allen bolts that secure the
lower bridge cover to the
upper bridge cover.
7. Tilt the lower bridge cover to
either side of the unit to
enable the lower bridge
cover to clear the upright
bolt heads
8. Remove the lower bridge
cover.
9. Install the new lower bridge
cover in the reverse order
using the bolts removed and
saved in steps 5 and 6.
32
Allen Screws (10)
Lower Bridge Cover

How To
HOW TO REPLACE THE OUTSIDE HANDRAIL COVERS

outlet.
3. Remove the cup holders. See the How
To on page 25.
4. Remove the inside handrail cover. See
5. Remove the Activity Zone assembly. See
6. Remove the lower bridge cover. See the
How To on page 32.
7. Remove and save the six Allen bolts that
secure the outer handrail cover to the
handrail.
8. Remove the outer handrail cover.
9. Install the new outer handrail cover
using bolts removed and saved in step 7.
Handrail
Outer Handrail Cover
33

How To
HOW TO... REPLACE THE UPPER BRIDGE COVER

outlet.
To on page 25.
4. Remove the console assembly. See
How To on page 28.
5. Remove the console neck spacer. See
How To on page 29.
6. Remove the inside handrail covers. See
How To on page 32.
9. Remove the outer handrail covers. See
10. Remove and save the six bolts that
secure the upper bridge cover to the
bridge frame.
11. Remove the upper bridge cover.
12. Install new upper bridge cover in
reverse order using the bolts removed
34

How To
HOW TO... REPLACE THE HANDRAIL

Tools required: 4mm Allen wrench, 8mm Allen wrench, mini flashlight
outlet.
To on page 25.
4. Remove the inside handrail covers. See
Screw (2)
Ergo Bar
Handrail

How To on page 32.
7. Remove the outer handrail covers. See
8. Remove and save the two bolts that
secure the handrail to the Ergo bar.
9. Remove and save the two Allen bolts
that secure the handrail to the upright.
10. Remove the handrail.
Allen Bolt (2)
11. Install the new handrail in the reverse

order using the bolts removed and saved
in steps 8 and 9.
35

How To
HOW TO... REPLACE THE HEART RATE HAND SENSORS

Tool required: Phillips screwdriver
1. Remove and save the two
Phillips screws that secure
each set of heart rate
electrodes to the Ergo bar.
Heart Rate Hand Sensor

(right hand assembly shown)
2. Note which wires go to the top

electrode and which go to the
bottom electrode.
3. Disconnect the wires from
both electrodes.
Upper Heart
Rate Assembly
4. Plug the wires into the new

electrodes.
5. Position the electrode gaskets
between the electrodes and
the Ergo bar.
6. Install the new electrodes in
the Ergo bar, using the screws
removed and saved in step 1.
7. Test the unit to verify that the
new electrodes are working
properly.
36
Upper Gasket
Lower Gasket
Phillips
Screw (2)
Ergo Bar
Heart Rate Sensor
Connectors (2)
Lower Heart
Rate Assembly

How To
HOW TO... REPLACE THE ERGO BAR ASSEMBLY

off.
wall outlet.
3. Remove the cup holders. See the
How To on page 25.
4. Remove the inside handrail
covers. See the How To on
page 31.
5. Remove the Activity Zone
assembly. See the How To on
page 30.
Screws to
bridge frame (3)
Washers (3)
Washers (2
on each side)
Screws to
handrails (2
on each side)
6. Remove the lower bridge cover.

See the How To on page 32.
7. Remove the outer handrail
covers. See the How To on
page 33.
8. Remove and save the four bolts
that secure the Ergo bar to the
handrails.
9. Remove and save the three bolts
that secure the Ergo bar to the
bridge frame.
10. Disconnect the heart rate cable
from the Ergo bar to the console.
11. Install the new Ergo bar assembly
in reverse order using the
hardware removed and saved in
steps 8 and 9.
When reattaching the Ergo bar to the handrails, it is critical to maintain the
proper bolt angle to prevent stripping the threads.
37

How To
HOW TO... REPLACE THE TOP MOTOR SHROUD COVER

Tool required: Phillips screwdriver
1. Remove and save the six Phillips screws
that secure the top motor shroud cover
to the motor cover mounting brackets
and frame.
2. Install the new top motor shroud cover
using the Phillips screws removed and
saved in step 1.
38

How To
HOW TO... REPLACE THE UPRIGHT COVERS

Tools required: Phillips screwdriver
1. Remove the top motor shroud cover. See
the How Toon page 38.
2. Remove and save the two Phillips screws
that secure the upright cover to the
upright.
3. Loosen the screw securing the upright
cover to the main frame (in front of the
upright).
4. Remove the upright cover.
5. Install the new upright cover in reverse
order, using the screws removed and
saved in step 2.
Screw (2)
Right Upright Cover
39

How To
HOW TO... REPLACE THE UPRIGHTS

Tools required: Phillips screwdriver, 4mm Allen wrench, 8mm Allen wrench
2. Unplug the line cord from the wall outlet.
3. Remove the top motor cover. See the How
To on page 38.
4. Remove either the right or left upright shroud
depending on which upright is being
replaced. See the How To on page 40.
5. Remove the inside handrail covers. See the
How To on page 31.
6. Remove the Activity Zone assembly. See the
How To on page 30.
7. Remove the outer handrail covers. See the
How To on page 33.
8.
Remove the lower bridge cover. See the

How To on page 32.
9. Remove and save the six upper bolts (three

per upright) that secure the bridge to the
uprights.
40
Bridge
Right
Upright
Left Upright
Allen Bolt (3
for each upright)

How To
HOW TO... REPLACE THE UPRIGHTS - CONTINUED

10. Cables run through both of the uprights.
Depending on which upright is being
replaced, the appropriate cable must be
disconnected. If replacing the left upright,
this will require disconnecting the power
cables to the attachable TV and rerouting
them through the new upright. The
transformer cable also must be removed
and rerouted if the left upright is being
replaced.
11. Carefully lift the bridge frame assembly
up and out of the uprights and set it to
the side.
12. Remove and save the three lower bolts
that secure the upright to the base frame.
13. Install the new upright in reverse order
using the hardware removed and saved in
the previous steps.
41

How To
HOW TO... REPLACE THE MAIN CABLE

outlet.
3. Remove the top motor cover. See the
How To on page 38.
How To on page 32.
6. Disconnect one end of the main cable
from the motor controller.
7. Disconnect the cable between the top of
the left upright and the console.
8. Pull the main cable out of the left
upright.
9. Install the new main cable in reverse
order.
Motor
Controller
Main Cable
Connector
42
Main Cable

How To
HOW TO... REPLACE THE BOTTOM MOTOR SHROUD COVER

1. Remove the top motor shroud cover.
2. Remove and save the four Phillips
screws that secure the bottom motor
shroud cover to the motor cover
mounting brackets.
Upper Motor Shroud
3. Install the new bottom motor shroud

cover in reverse order using the screws
removed and saved in step 2.
Lower Motor
Shroud Screws
(2 of 4 shown)
Lower Motor Shroud
43

How To
HOW TO... REPLACE THE REAR END CAPS

1. Remove and save the two Phillips
screws that secure the right or left
rear end cap to the frame.
2. Install the new rear end cap using the
screws removed and saved in step 1.
44

How To
HOW TO... REPLACE THE LOWER EXTRUSIONS

1. Remove the corresponding right or left rear
end cap. See the How To on page 44.
Upper Extrusion
2. The lower frame extrusion is attached to the

frame by a series of Velcro strips mounted
along the length of the frame. Separate the
Velcro strips and pull the lower frame
extrusion out and away from the side of the
treadmill.
Rear
End
Cap
3. Save the foam strip that is positioned

between the upper and lower extrusions.
4. Install the new lower frame extrusion in
reverse order.
Foam Strip
5. Install the foam strip by pressing it into the

space between the lower and upper frame
extrusions.
Lower Extrusion
Lower Extrusion
Velcro Strip
(one of four)
Upper Extrusion
Cross-section
Foam Strip
Lower Extrusion
45

How To
HOW TO... REPLACE THE UPPER EXTRUSION/ANTI-SLIP PAD ASSEMBLIES

Tools required: Phillips screwdriver, small flat blade screwdriver
1. Remove the top motor shroud cover.
Anti-slip Pad
2. Remove the upright shroud. See the

How To on page 39.
3. Remove the Phillips screws that secure
the motor cover mounting bracket to the
upper extrusion.
Upper Extrusion
4. Note the location of the anti-slip pad.

5. Using a small flat blade screwdriver,
carefully pry up one end of the anti-slip
pad.
6. Continue to peel the anti-slip pad until it
is completely removed from extrusion.
7. Remove the lower extrusion. See the
How To on page 45.
8. Remove and save the nine screws that
secure the upper extrusion to the frame.
46
Upright
Cover

How To
HOW TO... REPLACE THE UPPER EXTRUSION/ANTI-SLIP PAD ASSEMBLIES CONTINUED

9. Install the new upper extrusion to the
frame using the screws removed in step 8.
10. Peel the backing off the anti-slip pad.
11. Position the pad on the upper extrusion,
using the locating tabs on the back of the
anti-slip pad.
rectangular holes
for anti-slip pad
locating tabs
12. Press down firmly on anti-slip pad to

adhere it securely to the extrusion.
47

How To
HOW TO REPLACE THE FRONT ROLLER ASSEMBLY

Tools required: Phillips screwdriver, flat blade screwdriver, 5/32 Allen wrench, 5/16 Allen wrench, 9/16 socket, 3/8
ratchet, 5 long (12.7cm) 5.5mm Allen wrench
outlet.
3. Loosen the rear roller tensioning bolts to
relieve tension on the striding belt.
Count the number of rotations. This will
simplify re-tensioning the striding belt
later.
5. Remove the bottom motor shroud cover.
6. Insert a flat blade screwdriver into the
slotted end of the idler bracket.
7. Raise the idler bracket just enough to
insert the 5 (12.7cm) long 5.5mm Allen
wrench into the access hole of the idler
bracket. This will keep it in a raised
position.
Frame
Allen Wrench
Idler Arm
Idler Arm Access Hole
48

How To
HOW TO REPLACE THE FRONT ROLLER ASSEMBLY CONTINUED

8. Walk the drive belt off the drive motor
sheave and front roller pulley.
9. Remove and save the 9/16 bolt that secures
the left side of the front roller to the frame.
10. Slide the left end of the front roller as far as
possible toward the left side of the frame.
11. The right side of the front roller will now
clear the access hole in the right side of the
frame.
12. Remove the front roller from under the
striding belt.
13. Remove and save the four bolts and washers
that secure the drive pulley to the front
roller.
14. Install the removed drive pulley onto the new
front roller using the hardware removed and
saved in step 13.
15. Install the new front roller assembly.
Drive Pulley Bolts (4)
16. Install the drive belt onto the front roller

pulley and drive motor sheave.
17. Remove the 5 (12.7cm) long 5.5mm Allen
wrench from the idler bracket.
18. Lower the idler bracket and remove the flat
screwdriver from the idler bracket slot.
19. Tension the striding belt. See the How To
on page 70.
49

How To
HOW TO... REPLACE THE DRIVE BELT

Tools required: Phillips screwdriver, flat blade screwdriver, 5 (12.7cm) long 5.5mm Allen wrench, socket wrenches
outlet.
3. Loosen the rear roller tensioning bolts to
relieve tension on the striding belt.
Count the number of rotations. This will
simplify re-tensioning the striding belt
later.
5. Remove the bottom motor shroud cover.
slotted end of the idler bracket.
Rear Roller
Tensioning Bolts
7. Raise idler bracket just enough to insert

the 5 (12.7cm) long 5.5mm Allen
wrench into the access hole of the idler
bracket. This will keep it in a raised
position.
Frame
Allen
Wrench
50
Idler Arm
Access Hole
Idler Arm

How To
HOW TO... REPLACE THE DRIVE BELT CONTINUED
8. Walk the drive belt off the drive motor

sheave.
9. Remove and save the 9/16 bolt that
secures the left side of the front roller
to the frame.
10. Slide the left end of the front roller as
far as possible toward the left side of
the frame.
11. The right side of the front roller will
now clear the access hole in the right
side of the frame.
12. Remove the old drive belt from the
front roller pulley.
13. Install the new drive belt onto the front
roller pulley and drive motor sheave
locating the belt to the right side of the
front roller pulley and centered on the
drive motor pulley.
Front
Roller
Bolt
14. Re-install the front roller bolt.

15. Remove the Allen key from the idler
bracket and lower the idler bracket.
16. Remove the flat blade screwdriver from
the slot in the idler bracket.
17. Tension the striding belt. See the How
To on page 70.
51

How To
HOW TO... REPLACE THE IDLER BRACKET ASSEMBLY

Tools required: Phillips screwdriver, large flat blade screwdriver, 6mm Allen wrench, 13mm socket, 1/4 ratchet,
needle nose pliers, 5 (12.7cm) long 5.5mm Allen wrench
off.
outlet.
3. Remove the top motor cover. See
4. Remove the seven bolts that
secure the support bracket to the
motor pan.
5. Remove the support bracket and
set aside.
6. Remove the drive belt. See the
How To on page 50.
7. Disconnect the idler spring with
the needle nose pliers.
8. Remove and save the clevis pin
that secures the idler bracket
assembly to the motor pan frame.
9. Remove the idler bracket assembly
by lifting it straight up and off the
motor pan frame.
10. Install the new idler bracket
assembly in reverse order, using
the hardware removed and saved
in the previous steps.
52
Idler
Bracket
Clevis
Pin
Idler
Spring
Support
Bracket

How To
HOW TO... REPLACE THE DRIVE MOTOR

Tools required: Phillips screwdriver, flat blade screwdriver, 3mm Allen wrench, 6mm Allen wrench, 13mm socket,
14mm socket, 3/8 long extension, 3/8 ratchet, 13mm long 5.5mm Allen wrench
Estimated time required: 1 hour
outlet.
How To on page 38.
4. Remove and save the seven bolts that
secure the support bracket to the
motor pan. Do not remove the bar
tie.
5. Disconnect the cables between the
drive motor and the motor controller.
6. Remove the drive belt. See the How
To on page 50.
7. Remove the idler bracket assembly.
8. Scribe the location of the drive motor
on the insulating pads.
9. Scribe the position of the insulating
pads on the frame. This and the
previous step will aid in positioning
the new drive motor and
re-tensioning the motor drive belt.)
Drive Motor Bolt

(2 on each side
of motor)
Insulating
Pad
Motor
Pan
53

How To
HOW TO... REPLACE THE DRIVE MOTOR CONTINUED

10. Remove and save the four
hex nuts and washers that
secure the drive motor to
the motor mounting studs in
the frame.
Drive Motor
Flywheel/Fan Assembly
Bolt
11. Lift the drive motor

assembly up and off the
studs and out of the motor
pan.
12. Loosen the setscrews on the
drive motor sheave.
13. Remove the sheave from
the drive motor.
14. Loosen the setscrews that
secure the flywheel/fan
assembly to the drive
motor.
15. Remove the flywheel/fan
assembly and set aside.
Hex Nut (1
of 4 shown)
Drive
Belt
Drive
Sheave
54
Insulating
Pads (2)
Hex Nut (1
of 4 shown)

How To

16. Install the previously removed
flywheel/fan assembly and drive sheave
onto the new drive motor. Use Loctite
242 on the flywheel setscrews. (Do not
tighten the drive sheave setscrews until
the alignment procedure is complete
(see step 19).
Drive Sheave
17. Install the new drive motor in reverse

order, using the locations scribed in
steps 8 and 9 as mounting references.
Reuse any hardware removed and saved
in previous steps.
18. Slide the drive motor sheave onto the
motor shaft.
Drive Sheave
Setscrews (2)
Key
55

How To

19. To align the drive motor sheave
with the front roller pulley:
a. Using a straightedge, align the
outer face of the drive motor
sheave with the outer face of
the front roller pulley.
b. If necessary, slide the drive
motor sheave in or out on the
shaft.
c. Tighten one of the two
setscrews on the drive motor
sheave.
d. Remove the other setscrew and
apply Loctite 242 to its threads.
e. Insert and tighten that setscrew
in the sheave.
f. Remove the first setscrew.
g. Apply Loctite 242 to its threads.
h. Insert and tight the first
setscrew.
i. Repeat this procedure with the
front roller pulleys setscrews.
20. Re-install the Idler bracket and
drive belt.
56
Front
Roller
Pulley
Drive Motor
Sheave
Straightedge

How To
HOW TO... REPLACE THE LIFT MOTOR

Tools required: Phillips screwdriver, 10mm socket, 13mm socket, 14mm socket, 1/4" extension, 3/8 extension, 1/4"
ratchet, 3/8 ratchet
Lift Motor

3. Remove the top motor cover. See the How
To on page 38.
4. Remove and save the nine bolts that secure
the bar tie to the frame. Do not remove
support bracket.
Bolt
Nut
5. Disconnect the lift motor cable from the

motor controller.
6. Disconnect the lift motor ground wire from
the frame.
7. Carefully tilt the treadmill on its side.
8. Remove and save the nut and bolt that
secure the lift motor to the lift frame.
9. Remove the clevis pin that secures the lift
motor to the motor pan.
10. Remove lift motor from unit.
Lift Frame
11. Install the new lift motor in reverse order

using the hardware removed and saved in
the previous steps.
57

How To
HOW TO... REPLACE THE MOTOR CONTROLLER

Tools required: Phillips screwdriver, 8mm socket, long 1/4 extension, 1/4 ratchet
How To on page 38.
4. Record the cable connection locations.
5. Disconnect all cable connections to the
motor controller.
6. Loosen the three hex nuts that secure the
motor controller to the motor pan.
7. Remove and save the two bolts that secure
the motor controller bracket to the lift
motor bracket.
8. Remove the motor controller.
9. Install the new motor controller in reverse
order using hardware removed and saved
in the previous steps.
58
Lift Motor Bracket

(attached to bar tie)
Hex Nut (3)
Motor Controller
Motor Pan
Bolt (2)

How To
HOW TO... REPLACE THE ON/OFF SWITCH

Tools required: Phillips screwdriver, 8mm socket, 1/4 ratchet, long 1/4 extension, needle nose pliers
off.
outlet.
4. Record the location of wire
connections to the on/off switch.
5. Disconnect the wires. Use needle
nose pliers if necessary. (Some
techs may need to remove the
motor controller to allow more
room to access the on/off switch.)
6. Squeeze the tabs on the top and
bottom of the on/off switch and
push out from inside the frame.
7. Install the new on/off switch in
reverse order.
On/Off Switch
59

How To
HOW TO... REPLACE THE LINE FILTER

Tools required: Phillips screwdriver, 8mm socket, 1/4 extension, 1/4" ratchet
off.
wall outlet.
4. Remove the motor controller. See
5. Record the locations of the wires
connected to the line filter.
6. Remove the wires.
7. Remove and save the two Phillips
screws that secure the line filter
to the motor pan assembly.
8. Remove the line filter.
9. Install the new line filter in
reverse order, using the hardware

removed in step 7.
60
Phillips Screw
(1 of 2)
Line Filter

How To
HOW TO... REPLACE THE IEC RECEPTACLE

Tools required: Stubby Phillips screwdriver, 8mm socket, 1/4 ratchet, a long 1/4 extension, 4 X 4 wood blocks
outlet.
3. Lift the end of the treadmill about four
inches off the floor and place blocks of
wood under both sides to support it.
4. Remove and save the two screws that
secure the line cord retaining bracket to
the motor pan. Set the retaining bracket
aside.
5. Unplug the line cord from the unit and
save.
6. Remove top motor shroud cover. See the
How To on page 38.
7. Remove the motor controller. See the
How To on page 58.
Line Cord Retaining Bracket
61

How To
HOW TO... REPLACE THE IEC RECEPTACLE - CONTINUED

8. Record the location of the wires
connected to the IEC connector
9. Disconnect the wires.
10. Remove and save the two screws that
secure the IEC connector to the motor
pan.
11. Remove the IEC connector.
12. Install the new IEC connector, using the
hardware removed and saved in previous
steps.
Screw (2)
62
IEC Receptacle

How To
HOW TO... REPLACE THE HOME SWITCH

Tools required: Phillips screwdriver, 8mm socket, 1/4 ratchet, 1/4 extension
outlet.
Home Switch

How To on page 38.
4. Remove the motor controller. See the
How To on page 58.
5. Remove and save the hex nuts that
secure the home switch to the studs on
the frame. (The bar tie may have to be
removed.)
6. Remove the home switch bracket
assembly from the frame studs.
7. Disconnect the wires to the home
switch.
8. Separate the home switch from the
bracket. Save the bracket.
9. Install the new home switch on the
bracket.
10. Install the new home switch with
bracket in reverse order using the
hardware removed and saved in the
previous steps.
63

How To
HOW TO... REPLACE THE REAR ROLLER GUARDS

1. Remove and save the two screws
that secure the right or left rear end
cap to the frame.
2. Remove and save the two screws
that secure the rear roller guard to
the frame.
3. Install the new rear roller guard in
reverse order using the hardware
removed in previous steps.
Rear Roller Guards
Phillips Screw (2)
64

How To
HOW TO... REPLACE THE REAR ROLLER ASSEMBLY

Tools required: Phillips screwdriver, 5/16 Allen wrench
outlet.
3. Remove the rear end caps. See the
How To on page 44.
4. Remove the rear roller guards. See the
How To on page 64.
5. Remove and save the belt tensioning
screws from the rear roller. Count the
number of rotations. This will simplify
re-tensioning the striding belt later.
6. Remove the rear roller from under the
striding belt.
7. Install the new rear roller in reverse
order, using the hardware removed and
saved in previous steps.
8. Adjust the striding belt tracking. See
Rear Roller
Tensioning Bolts
Striding Belt
Rear Roller
65

How To
HOW TO... REPLACE THE STRIDING BELT AND DECK

Tools required: Phillips screwdriver, 5/32 Allen wrench, 5/16 Allen wrench, 9/16 socket, 3/8 extension, 3/8
ratchet, large flat blade screwdriver, 5 (12.7cm) long 5.5mm Allen wrench
off.
outlet.
Left Roller Guard
3. Remove the rear end caps. See the

How To on page 44.
4. Remove the roller guards. See the
How To on page 64.
Right Roller Guard

6. Remove and save the tensioning
screws from the rear roller. Count
the number of rotations. This will
simplify re-tensioning the striding
belt later.
66
Washer (2)
Rear Roller
Adjusting Screws
Roller Guard
Screw (2)

How To
HOW TO... REPLACE THE STRIDING BELT AND DECK - CONTINUED

7. Remove the rear roller from under the
striding belt just enough to mark the
right end of the shaft with the letter
R with a felt-tip marker so that it can
be reinstalled in the same left-right
orientation. This will maintain the same
bearing wear pattern.
8. Remove the four corner deck bolts that
secure the deck to the frame.
9. Remove the deck from under the
striding belt. Be careful not to hit the
Stride Sensor assembly with the deck.
slotted end of the idler arm. Raise the
idler arm just enough to install the 5
(12.7cm) long 5.5mm Allen wrench into
the access hole of the idler arm to keep
the idler bracket in a raised position.
11. Walk the motor drive belt off the drive
motor sheave and the front roller
pulley.
12. Remove and save the bolt and washers
that secure the left side of the front
roller to the frame.
13. Slide the left end of the front roller
shaft as far as possible toward the left
side of the frame. The other end of the
front roller will now clear the access
hole in the right side of the frame.
Striding Belt
Striding
Belt
Front Roller
Mounting Bolt
Letter R
Rear Roller
Deck
Screws (4)
Deck
Lock Washer
Flat Washer
Front Roller
Rear Roller
Rear Roller
Adjusting Screws (2)
Belt Barrier
14. Remove the motor drive belt from the

front roller pulley.
15. Remove the front roller from under the
striding belt.
67

How To

16. Remove the striding belt.
17. Position the new striding belt inside the unit.
The arrow on the inside of the belt must point in the direction of belt rotation.
18. Position the front roller under the

striding belt.
19. Place the right side of the front roller
shaft in the access hole.
20. Secure the left side of the front roller
with the mounting bolt and washers
removed in step 12.
21. Reinstall the motor drive belt.
22. Install the new deck (or the existing
deck, flipped) from the left side of the
treadmill.
23. Secure the deck with the four mounting
screws.
24. Remove any wax build-up on the rear
roller using a plastic scraper or plastic
putty knife.
25. Position the rear roller under the
striding belt. Orient the roller so that
the R identification mark at the end
of the roller shaft is positioned on the
right-hand side of the machine.
68
Striding Belt
(loosened)
Deck

How To

26. Secure the rear roller tensioning bolts
by hand. Do not tighten these bolts. The
belt should remain loose. foresee
27. Adjust the striding belt tension and
tracking following the procedures on the
following pages.
28. Reinstall the top motor cover.
29. Log the replacement of the striding belt
and/or deck in the maintenance repair
log in Diagnostics.
69

How To
HOW TO...TENSION A STRIDING BELT

Tools required: Allen wrenches
1. Center the loose striding belt on the
front and rear rollers.
2. Position the belt within the belt
barriers.
3. Place two pieces of masking tape
exactly 38 1/2 (977 mm) apart on the
right and left edges of the striding belt
as shown (four pieces total).
4. To tension the belt, tighten the
tensioning bolts until the distance
between the tapes (on both sides) is
increased to 38 3/4 (984 mm) for a
brand new striding belt and 38 3/8
(974mm) for an existing striding belt.
Tape
38 ( 974 mm )
Tape
5. Adjust the striding belt tracking. See

38 34 (984 mm)
70

How To
HOW TO...ADJUST THE STRIDING BELT TRACKING

Tools required: Allen wrenches
1. Turn the treadmill power switch on.
2. Run the striding belt speed at 2.5 mph
(4.0 km/h).
3. If the striding belt has moved to the
right, turn the right tension bolt 1/8turn clockwise and the left tension bolt
1/8-turn counterclockwise, (as shown in
the illustration) to start moving the
striding belt back to the center of the
rear roller.
4. If the striding belt has moved to the left,
turn the left tension bolt 1/8-turn
clockwise and the right tension bolt1/8turn counterclockwise (opposite the
direction shown in the illustration) to
start moving the striding belt back to the
center of the rear roller.
5. Repeat this adjustment until the striding
belt is centered. Allow the unit to
operate for several minutes to see that
the belt remains centered.
71

How To
HOW TO... REPLACE THE LIFESPRINGS

Tools required: 5/32 wrench, 5/16 wrench
outlet.
3. Loosen the rear roller tensioning bolts
until the striding belt is slack enough to
allow removal of the deck. Count the
number of rotations. This will simplify
re-tensioning the striding belt later.
4. Remove and save the four corner deck
mounting bolts.
LifeSprings (4
on each side)
5. Carefully remove the deck. Be careful

not to damage the Stride Sensor
assembly with the deck.
6. Remove the screw that secures the
LifeSpring to the frame.
Stride Sensor Assembly
7. Remove the LifeSpring from the

treadmill frame. Do not save the
Tinnerman clip on the LifeSpring.
8. Install the new LifeSpring in reverse
order, using the screw removed in step
6. Orient the LifeSpring with the notch
facing the inside of the treadmill. Use a
new Tinnerman clip (not included with
the new LifeSpring).
9. Tighten the LifeSpring mounting screws
to 27-33 in-lbs (3.0-3.7 Nm).
LifeSpring
Tinnerman Clip
72

How To
HOW TO... REPLACE THE STRIDE SENSOR ASSEMBLY

Tools required: Phillips screwdriver, 5/32 Allen wrench, 5/16 Allen wrench
outlet.
4. Disconnect the Stride Sensor
assembly cable from the motor
controller.
5. Attach a heavy cord or twine about
3 feet (1 meter) long to the
disconnected Stride Sensor
assembly.
LifeSprings (4
on each side)
6. Loosen the rear roller tensioning

screws until the striding belt is slack
enough to allow removal of the
deck. Count the number of
rotations. This will simplify retensioning the striding belt later.
7. Remove and save the four corner
bolts that secure the deck to the
LifeSprings.
8. Carefully remove the deck from
under the striding belt.
9. Remove and save the screw that
secures the Stride Sensor assembly
to the frame.
Phillips Screw
Frame
LifeSpring
73

How To
HOW TO... REPLACE THE STRIDE SENSOR ASSEMBLY CONTINUED

10. Remove the Stride
Sensor assembly by
carefully pulling the
cable out of the frame
until the cord or twine
tied to the end of the
cable is exposed.
11. Attach the cord or
twine to the new
Stride Sensor assembly
cable and feed it
through the frame
until the connector is
exposed.
12. Install the Stride
Sensor assembly to the
frame using the screw
removed and saved in
step 9.
13. Install the remaining
components in reverse
order.
74

How To
HOW TO... REPLACE THE REAR TOE GUARD

Tools required: Phillips screwdriver, 6mm Allen wrench, 1/2 socket, 3/8 ratchet
1. Remove the rear end caps. See the How
To on page 44.
2. Remove and save the two Allen bolts and
two hex nuts that secure the rear toe
guard to the frame.
3. Remove the rear toe guard.
4. Install new rear toe guard using
hardware removed and saved in step 2.
Rear Toe Guard

Allen Bolts (2)
75

How To
76
ELECTRONICS

Electronics
DSP CONTROLLER BOARD

Personnel must be trained and adequate precautions must be taken whenever
working on this equipment. Considerable energy is stored in it for up to ninety
seconds after it is removed from the circuit. Wait two full minutes after the unit
is turned off before performing any procedures.
Description
Location
Service LED
LED1
LED2
LED3
LED4
LED5
LED6
LED7
LED8
LED9
LED10
Connector
P1 is a 6 Position
female Mate-NLock connector
for Motor
P4 is a 4 Position
Mini-Fit Jr., for
Home Switch
Function
12VDC indicator
8VDC indicator
Tx Communication indicator
Lift (Up) direction
Lift ON
V bus indicator
+VDC indicator
3.3VDC indicator
Incline 0 position indicator
Incline Bottom position indicator
Pin
Functional Description
1
2
3
4
5
6
1
GND
Motor phase W
Motor phase V
Motor phase U
Not Used
Not Used
Zero position switch
Zero position switch return (GND)
Bottom limit switch
Bottom limit switch return (GND)
79

Electronics
DSP CONTROLLER BOARD - CONTINUED
Connector
P5 is a 10 Position MateN-Lock connector for

Console power and
signal
P6 is a 4 Position MateN-Lock connector for

Lift Actuator
P7 is a 3 Position MiniFit Senior for AC Input

Power input
P8 is a 2 Position MiniFit Jr. for Motor
Thermal Switch
80
Pin
RTN
RTN
8VDC
8VDC
Not used (LED) or 12V (LCD)
RXD (Receive Data)
TXD (Transmit Data)
Not used
12 VDC
10
ESS (Emergency Stop Switch)
Down
Hot
Up
Not Used
Line
Neutral
Not Used
Therm1 = ESS Out
Therm2 = ESS In

Electronics
DSP CONTROLLER BOARD - CONTINUED
Connector
P9 is a 5 Position MiniFit Jr. for console
voltage select
3 position C-grid
connector for Stride
Sensor interface
P11 is a Faston
connection for 200-240V
only
P12 is a Faston
only
P13 is a Faston
only
P16A is a Faston
connection
P16B is a Faston
connection
Pin
1
2
3
4
5
8VDC
6/8VDC
6VDC
12VDC
12V (ESS)
RTN
SSENSE
+12VDC
Autotransformer return
Autotransformer out (120)
Autotransformer in (100-200-220/230240VAC)
Vbus (brake)
Bus return (brake)
81

Electronics
POWER COMPONENTS SCHEMATIC

120V
GRN/YLW
BLACK
WHITE
ON/OFF
SWITCH
200 - 240V
HOT
WHITE
GND
POWER
CABLE TO
DSP MOTOR
GRN/YLW
NEU
MOV
LINE
LOAD
BLACK
GRN/YLW
82
WHITE
ON/OFF
SWITCH
HOT
GND
POWER
CABLE TO
DSP MOTOR
GRN/YLW
NEU
MOV
LINE
LOAD
BLACK

Electronics
BLOCK DIAGRAM
83

Electronics
84
INDEX

Index
INDEX
Activity Zone, 9, 13
Activity Zone assembly,
replacing, 30
anti-slip pad, 13
deck, 13
display console, 9
drive belt, 15
drive motor, 9
drive motor,
replacing, 54
DSP motor controller, 9,
13, 79
glossary, 14
grinding noise during
footfall, 20
grinding noise during
incline, 20
B
belt squeaking noise, 20
block diagram, 83
blocks, 11
bottom motor shroud cover,
replacing, 43
bucket, 13
C
cable tie, 13
connector, 13
console, 13
console assembly,
replacing, 28
cord, 11
console displays a heart rate
reading but no signal, 22
console, no power, 17
console neck spacer,
replacing, 29
corrective action, 19
cup holders, replacing, 25
customer support,
contacting, 7
H
E
EEPROM, 13
electromechanical, 14
electronics, 9
EPROM, 13
Ergo bar, 13
Ergo bar assembly,
replacing, 37
ESD, 13
handrail, replacing, 35
heart rate hand sensors,
replacing, 36
heart rate reading on
display but no signal
on console, 22
heart rate transmitter
not detected, 22
heat sink, 13
home switch, 13
home switch,
replacing, 63
F
fax, 7
flash memory, 13
frame, 9
front roller, 13, 48
I
idler bracket assembly,
replacing, 53
IEC, 13
IEC receptacle,
replacing, 61
inside handrail covers,
replacing, 31
integrated circuit, 13
87

Index
INDEX - CONTINUED
J
jumper, 13
main cable, replacing,

42
main wire harness, 14
manual, how to use, 5
MET, 14
mini flashlight, 11
model number, 7
motor controller, 14
motor controller,
replacing, 58
motor drive belt,
replacing, 51
mph, 14
multimeter, 11
phone, 7
pliers, 11
Polar receiver, 14
power components
schematic, 82
power off, console, 17
power off, treadmill, 17
PWM, 14
K
km/h, 13
knocking noise, 20
L
LED, 14
leveler, 14
Lifepulse, 14
Lifepulse,
incorrect reading, 21
Lifepulse,
non-responsive, 21
LifeSpring, 14
LifeSprings, replacing, 73
lift motor, 14
lift motor,
incline, 9,21
lift motor,
replacing, 57
line cord, replacing, 26
line filter, replacing, 60
Loctite, 11
loopback test, 14
lower bridge cover,
replacing, 32
lower extrusions,
replacing, 45
N
no power, console, 17
no power, treadmill, 17
O
on/off switch,
replacing, 59
operation, theory of, 9
outside handrail covers,
replacing, 33
R
rear console cover,
replacing, 27
rear end caps,
replacing, 44
rear roller, 14
rear roller assembly,
replacing, 65
rear roller guards, 14
rear roller guards,
replacing, 64
rear toe guard,
replacing, 76
reduced maximum
speed, 19
removable thread locking
compound, 11
rpm, 14
rubber mallet, 11
rubbing sound under the
treadmill, 20
S
screwdrivers, 11
serial number, 7
service tools, 11
single-phase AC, 14
snap ring pliers, 11
socket wrenches, 11
88

Index
INDEX - CONTINUED
S
(continued)
upper bridge cover,

replacing, 34
upper extrusion/anti-slip
pads, replacing, 46
upright covers,
replacing, 39
uprights, replacing,40
using this manual, 5
static current, 14
stop switch, 14
Stride Sensor, 14
Stride Sensor assembly,
replacing, 74
striding belt, 14
striding belt, adjust
tracking, 72
striding belt and deck, 9
striding belt, existing belt
tension adjustment, 71
striding belt, new belt
tension adjustment, 70
striding belt,
not centered, 21
striding belt,
replacing, 66
striding belt slips, 20
striding belt,
tracking limits off, 21
symptoms, 19
W
wax/lift board, 14
workout summary,
in middle of a
workout, 19
wrenches, 11
T
table of contents, 2
telemetry receiver, 14
telephone, 7
tension a striding belt, 70
theory of operation, 9
three-phase AC, 14
tools required, 29
top motor shroud cover,
replacing, 38
treadmill, no power, 17
treadmill pauses or resets
randomly, 19
troubleshooting, 17
twine, 11
89

Index
90
2007 Brunswick Corporation. All rights reserved. Life Fitness is a registered trademark of Brunswick Corporation.
Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation.
Any use of these trademarks, without the express written consent of Brunswick Corporation, is forbidden.
M051-00K65-A003
JULY 2008

Treadmill 95T-DOMLX-DOMHX-INTHX-01 - Service - Manual - M051 - 00K65-A003

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95T-DOMLX-01

Customer Support Services

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMX-01, and 95T-INTHX-01 Treadmills

TABLE OF CONTENTS CONTINUED

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

USING THIS MANUAL

Information that will prevent damage to the treadmill.

Information that will prevent personal injury or damage to the treadmill.

95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

CONTACTING CUSTOMER SUPPORT

Model and serial

95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

Rear roller guards

Miles per hour

Revolutions per minute

Producing, carrying, or powered by one alternating voltage

Steady flow of electricity

The electrical component used to terminate a workout routine

The component which detects a users impact on the deck

The moving part of the unit on which a user walks or runs

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

95T-DOMLX-01, 95T-DOMHX-01 and 95T-INTHX-01 Treadmills

Defective Line Cord

Defective power switch

Insufficient line voltage at

Defective line filter

Defective power switch

Defective DSP controller

95T-DOMLX-01, 95TDOMHX-01 and 95T-INTHX-01 Treadmills

Treadmill pauses or resets

Improperly seated power

Damaged or shorted main

Workout summary appears

Reduced maximum speed

Stop switch is false

Verify that all cable connections

95T-DOMLX-01, 95T-DOMHX-01 and 95T-INTHX-01 Treadmills

Faulty front or rear roller

Rubbing sound from under

Squeaking noise when belt

Grinding noise during

Striding belt not positioned

Worn or damaged main

Grinding noise on footfall

Excessive friction between

Striding belt slips

Incorrect striding belt

95T-DOMLX-01, 95TDOMHX-01 and 95T-INTHX-01 Treadmills

Striding belt not

Striding belt not tracking

Worn striding belt

Lift motor will only

DSP controller not receiving

Level the treadmill according to the