Life Fitness X5i Console Beeping Repair

Introduction: Life Fitness X5i Console Beeping Repair

About: I like electronics and programming.

This is how I fixed my Life Fitness x5i console beeping problem.

LEGAL DISCLAIMER: DO THIS AT YOUR OWN RISK. THESE STEPS INCLUDE MODIFYING THE CONSOLE OF THE MACHINE AND WILL MOST LIKELY VOID ANY WARRANTY.

The problem with my machine was that one of the keys on the membrane keyboard on the console was damaged and making partial contact.

Inside the console there is a 7 pin connector and a ribbon cable that connects it to the membrane switch keypad. Only 6 pins are used. They are labeled key0, key1, key2, key3, com0 and com1.

The key map is as follows:

com1/key0=my workouts, com1/key1=level up main console, com1/key2=enter, com1/key3=clear/pause, com0/key0=quickstart, com0/key1=workout profile, com0/key2=level down main console, com0/key3=cool down

Step 1: Remove Console From Elliptical

On mine there were two screws securing the console to the machine. Remove these.

Once the console is loose, remove the ribbon cables going into the base of the machine.

Step 2: Make Replacement Keypad

To make a new keypad you will need the following:

4x Momentary Switches
1x SPDT Switch
1x PCB Perfboard
1x Jumper Wire Kit
1x Dupont Wire Female to Female Breadboard Jumper Wires Ribbon Cables
1x Soldering Iron

Step 3: Modify Console Shell

Using a dremel or similar device, make a hole at the seam of the console to pass the ribbon cable through.

Step 4: Connect Ribbon Cable to Console

Step 5: Reassemble and Attach Console

I used double sided tape to secure the new keypad to the console.

Be the First to Share

    Recommendations

    • Fruit and Veggies Speed Challenge

      Fruit and Veggies Speed Challenge
    • Fandom Contest

      Fandom Contest
    • DIY Summer Camp Contest

      DIY Summer Camp Contest

    17 Comments

    0
    SonOfASeaCook
    SonOfASeaCook

    2 months ago

    Very impressive! Our Life Fitness Cross Trainer X5i began randomly beeping and sporadic displays for the past 2 years. The only way make it stop was unplugging it. In the beginning it was infrequent until recently it was so common the machine became unusable. I suspected the console control board was bad and read online where someone had his repaired for $350. But a few other bloggers discussed their power supply was bad. So I checked our power supply and sure enough, its output was 14.2 volts, not the required 9 volts. I ordered a new one on Amazon for (model MKD-48091000) for $13.96, the "Omnihil AC/DC Power Adapter Compatible with Life
    Fitness Model: MKD-48091000 Essential Cross-Trainer ITE Power Supply Adaptor". It arrived in 2-days and I tested it first to confirm it was good. Its output was 9.1 volts. When I connected it, our Life Fitness Cross Trainer X5i beeped about 6 times, and went into idle mode (not randomly beeping. yeah!) so far, it is working great. I was also able to perform all of the diagnostics mode tests listed in Section II of the Service Manual (found on www.manualslib.com).
    So if you're Life Fitness Cross Trainer is randomly beeping, test its power supply. Hopefully, your fix will be as easy as ours was.


    1
    norman_h
    norman_h

    6 months ago

    This can be done even more trivially - Just get yourself a 3x4 membrane matrix keypad, like https://www.amazon.com/dp/B07F31QP8V and plug it in.

    The extra C2 line which is stubbed out on the original header are the extra "Cross Training" mode buttons on the lower console, and is now duplicated on the 3 - # column

    1 = Quickstart
    2 = My Workout
    3 = CT Reverse
    4 = Profile
    5 = Up
    6 = CT Aerobics
    7 = Down
    8 = Enter
    9 = Down (Lower)
    * = Cooldown
    0 = Clear/Pause
    # = Up (Lower)

    (Original time-up and time-down buttons are still active and not on this header)

    2020-12-29.jpg
    0
    CrankyCat
    CrankyCat

    Reply 6 months ago

    Norman_h - I did this fix and it works great. Cheap,Easy,Fast!

    0
    jafont1958
    jafont1958

    9 months ago

    Thanks EdwardL91 for being the first I've seen to figure this out and HoogHouse for your subsequent thoughts. With your initial key mapping, my retired engineering buddy helped me (an inexperienced newbie) build an elegant solution with parts ordered on
    Amazon. It actually looks good on this machine! My wife even likes it!
    Also attaching a youtube link with my powerpoint that has my buddy's design, specific materials used, and pictures if anyone is interested: https://www.youtube.com/watch?v=NMYsTF0ey8o . It's shameful that LifeFitness designed a console with this design and they won't support it at all. However, with this community's help I've saved my $2,800 investment! Hope this helps others save their investment

    Final project image.jpgInside project box cropped.jpg
    0
    HoogHouse
    HoogHouse

    12 months ago

    Edward, okay...today we successfully did the 'temp repair' ... and now we are planning the full up repair. We used a quick cnc program to cut the wood and countersink the buttons. Now we will probably do a new cover with Lexan...or drill through the old plastic sheet to embed the final solution.

    Thanks again for your help and encouragement. You, sir, are awesome!

    9A518077-8D3B-411F-B6D8-301C9526AD08.jpeg63318FA0-A857-4B46-9978-C25D2C496CC3.jpeg
    0
    HoogHouse
    HoogHouse

    1 year ago

    Awesome! Do you have any "lessons learned" you'd do differently? We're about to embark on this journey. THANK YOU for posting your findings and your method.

    1
    EdwardL91
    EdwardL91

    Reply 1 year ago

    The repair is still working after 2 year, but if I were to do it again, I would probably use 8 momentary switches, omit the SPDT switch, and place the circuit in a small labeled project box.

    0
    HoogHouse
    HoogHouse

    Reply 1 year ago

    Why only 8, and not 10 momentary switches? Your overlay, like ours, has the "increase / decrease" time on the left. I presume that you determined that membrane part was not the cause? I've been inspecting the back of the overlay to see if I am able to determine by inspection which membrane switch is faulty.

    0
    EdwardL91
    EdwardL91

    Reply 1 year ago

    Yeah, I determined the increase/decrease part of the membrane was not at fault, and since it used a separate ribbon connector, opted not to include it in the new circuit.

    0
    HoogHouse
    HoogHouse

    Reply 1 year ago

    So, I'm thinking about drilling holes into the plastic behind the Membrane cover plate and using little switches like these, glued to the back of the console cover. I'd then run the wire matrix and connect a ribbon cable. Any thoughts? By the way, what did you use for the 7 pin female connector? Did you buy another, or reuse the one from the ribbon cable?


    s-l1600.jpg
    0
    EdwardL91
    EdwardL91

    Reply 1 year ago

    This type of switch is meant to be soldered to a circuit board. Check these panel mount style out https://www.adafruit.com/product/1505. The connectors you are asking about are called headers. The wire I used is DuPont wire. If you search for 'Arduino headers' and 'Arduino wire' you should find plenty of options.

    0
    HoogHouse
    HoogHouse

    Reply 1 year ago

    Thanks Edward!!

    0
    HoogHouse
    HoogHouse

    Reply 1 year ago

    Edward, we were pondering doing a prototype circuit board version to verify operation, and then, assuming all is good, physically mounting the switches to the plastic underneath the overlay.

    Your success has given us a lot more confidence to try this. I was really disheartened when the machine started the beeping. The only other info I could find online was from people who ended up having to purchase a new console. We were able to determine the console worked, just the input from the overlay was causing the problem

    Again, THANK YOU for taking the time to post your repair!

    0
    guineydale
    guineydale

    Question 1 year ago on Step 5

    I am really only looking to stop the beeping noise when starting up at 5am. My family members are not happy. Is there a way to silence the beep when pressing buttons? On this Life Fitness X5i machine.

    0
    HoogHouse
    HoogHouse

    Answer 1 year ago

    You could disconnect the beeper on the circuit board itself.

    0
    tomatoskins
    tomatoskins

    2 years ago

    Excellent repair!

    0
    EdwardL91
    EdwardL91

    Reply 2 years ago

    Thanks!