Life Fitness 9500 Series User manual

Life Fitness Model 9500 Series Cross-Trainers
Customer Support Services
SERVICE MANUAL

Life Fitness Model 9500 Series Cross-Trainers
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
Note: This service manual is applicable to Life Fitness model 9500 Lower Body and 9500HR Total Body Cross-Trainers.
The Service Manual provides instruction, guidance and recommendations on safe and efficient approaches to repair and
adjustment situations. The Manual is separated into six sections.
INTRODUCTION
THEORY OF OPERATION
TABLE OF CONTENTS
Section I
qTROUBLESHOOTING GUIDES
Section II
qDIAGNOSTIC TESTS
Section III
q"How To..." SERVICE AND REPAIR GUIDES
Section IV
qELECTRONICS OVERVIEW
qWIRING BLOCK DIAGRAMS
Section V
qPARTS IDENTIFICATION
Section VI
qMISCELLANEOUS INFORMATION
When an operating problem occurs, refer to troubleshooting guides and diagnostic tests in an attempt to isolate the cause.
When applicable, guides and tests are listed by symptom followed with suggestions of probable cause(s).
Once you have pinpointed the source of the problem, refer to "How To..." guides for recommended repair procedures. "How
To..." sub-sections are organized by replaceable part or assembly name. For convenience, sub-section lists recommended
“Tools Required” to complete each specific function.
Refer to the PARTS IDENTIFICATION section to identify proper name and number of part to order for repair of equipment.
A reproducible telefacsimile order claim form is provided in COMMUNICATING BY TELEFACSIMILE for convenient ordering
of service parts.
To order, contact Life Fitness Customer Support Services.
Via telefacsimile - 24 hrs. /day, 7 days/week.
Via telephone - Monday through Friday from 8:00 AM to 6:00 PM ( C.S.T.).
To speed Life Fitness Customer Support Services response to your needs, please be prepared to provide the following
information to the phone technician. 1. Model number
2. Serial number
3. Symptom of problem
4. Part name and number to order (if known)
CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue; Franklin Park, IL 60131; U.S.A.
Telephone: [phone] or Toll Free 800.351.3737 Telefacsimile: 847.288.3702 or Toll Free 800.216.8893
TM

Life Fitness Model 9500 Series Cross-Trainers
THEORY OF OPERATION
The electronics system of the CT-9500 Series Cross-Trainers, is made up of three distinct modules, the Power
Entry Module, the Display Console, and the Power Control Board.
120 volts AC enters the Power Entry Module. It passes through a transformer and is converted to 14 volts AC.
The 14 volts AC is applied to the Power Control Board at connector J4, pins 1 and 2. The voltage passes through a
bridge rectifier, BR1 and is converted to an unregulated positive DC voltage. This unregulated voltage will vary
from 11 volts DC to 18 volts DC depending on the wall supply and load. This voltage can be measured by placing
the positive probe of your DVM on Positive Test Point at BR1 and the negative probe on the negative Test Point at
BR1.
The other voltage developed on the Power Control Board is a regulated positive 8 volts DC. The regulated 8 volts
DC is developed by transistor (Q2) . This voltage can be measured by placing the positive probe of your DVM on
the collector(case) of Q2 and the negative probe on the anode of D1.
This 8 volts DC is supplied to the Console at connector J1, pin 4 and is used to power the LED’s. The 8 volts DC is
also used as a supply voltage for the positive 5 volt DC regulator (U1) on the Console board, which is VCC for the
Microprocessor. The Keypad entry (user’s input), Life Pulse (9500HR only), Telemetry, and the Stop Switch
functions are all processed by the Microprocessor.
The Console, by pulse width modulating the field control line, sends a signal to the Power Control Board at J1, pin
1. The Power Control Board switches the field current to the Alternator, through Q1. This field current along with
the energy supplied by the user is sent to the Load Resistors. This places resistance on the rotation, thus providing
the load sensation felt by the user.
The Alternator also provides the source for the RPM sensor circuit. The AC tap output on the Alternator enters the
Power Control Board at J2, pin 3. This AC voltage is wave conditioned and outputted at connector J1, pin 2 to the
Console connector P2, pin 6. Where it is processed and displayed by the Console.
PIN_PADSTA
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C
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1
C6
FU
SE
1
BR1
U3
HS3
HS1
HS4
C9
C5
Q1
D7
D6
J4
R9
R2
R1
R6R16 R4
R5
R15
R3
R14
R7
R8
R17
R18
C11
C14
C12
C13
C7
C8
U1 AC
POS
AC
WARNING:
RISK OF FIRE,REPLACE FUSE AS
MARKED.
Q2
C
1997
A080-92167-
A000
LIFE FITNESS
8
AM
P
S.B
.
25
0V
Neg
Q2
Pos
J4
14 VAC
8 VDC
+
_
D1
Neg
+
_
BR 1
18 VDC
J1 J2
ALTERNATOR
CONSOLE
Pin 3
RPM
Pin 4
8VDC
See Wiring Diagram for more detailed
information

Life Fitness Model 9500 Series Cross-Trainers
TABLE OF CONTENTS
SECTION I
TROUBLESHOOTING GUIDES PAGE
LOUD THUMPING NOISE............................................................................................... 2
RUBBING AND WHINNING NOISE................................................................................. 2
METAL NOISE................................................................................................................. 2
GRINDING....................................................................................................................... 2
RUBBING AND SQUEAKING .......................................................................................... 2
KNOCKING AND THUMPING.......................................................................................... 2
DRIVE BELT SLIPPING................................................................................................... 2
UPPER ARMS LOOSE.................................................................................................... 2
END PLAY IN PEADAL ARM........................................................................................... 3
ALTERNATOR BELT SLIPPING...................................................................................... 3
NO POWER..................................................................................................................... 3
NOT READING HEART RATE......................................................................................... 3
ERRATIC HEART RATE.................................................................................................. 4
NO LEDS......................................................................................................................... 4
NO RPM .......................................................................................................................... 4
ALTERNATOR BELT TENSION ...................................................................................... 5
NO LOAD......................................................................................................................... 6
SECTION II
DIAGNOSTICS
OVERVIEW ..................................................................................................................... 2
STATE 1: ALL LEDS AND KEYPAD TEST ...................................................................... 3
STATE 2: INDIVIDUAL LED TEST................................................................................... 4
STATE 3: PROGRAMVERSIONNUMBER ............................................................................ 5
STATE 3: VERSION #, RPM, HR, AND LOAD TESTS (INTEGRATED PCB) .................. 6
STATE 4: HEART RATE SOFWARE (MODEL 9500HR ONLY)....................................... 7
STATE 4: LIFEPULSE AND NETWORK STATUS TESTS (INTEGRATED PCB)............. 8
STATE 5: MAXIMUM PROGRAM DURATION................................................................. 9
STATE 6: TELEMETRY ENABLE/DISABLE..................................................................... 10
STATE 7: ENGLISH / METRIC UNITS............................................................................. 11
STATE 8: MODEL SELECTION....................................................................................... 12
STATE 9: TOTAL HOURS / STATISTICS........................................................................ 13
STATE 10: METS ENABLE / DISABLE............................................................................ 14
STATE 11: PAUSE TIME OUT ........................................................................................ 15
STATE 12: PHOTO SHOOT............................................................................................ 16
STATE 12: LANGUAGE SELECTION (INTEGRATED PCB)............................................ 17
STATE 13: EEPROM TEST (INTEGRATED PCB)........................................................... 18
STATE 14: PHOTO SHOOT (INTEGRATED PCB).......................................................... 19
NOTES............................................................................................................................ 20

Life Fitness Model 9500 Series Cross-Trainers
TABLE OF CONTENTS
SECTION III
HOW T0…REPLACE: PAGE
DISPLAY CONSOLE ASSEMBLY.................................................................................... 2
TRAY ASSEMBLY........................................................................................................... 3
READING RACK ASSEMBLY.......................................................................................... 4
STOP SWITCH ASSEMBLY............................................................................................ 5
HOOD SHROUD ASSEMBLY.......................................................................................... 6
HEART RATE UPPER ARM ASSEMBLY......................................................................... 7
UPPER ARM ASSEMBLY................................................................................................ 8
RIGHT SIDE SHROUD FOR HEART RATE UNITS......................................................... 9
RIGHT SIDE SHROUD FOR NON-HEART RATE UNITS................................................ 10
IDLER PULLEY TENSION BRACKET.............................................................................. 11
DRIVE BELT.................................................................................................................... 12
POWER CONTROL BOARD BRACKET ASSEMBLY...................................................... 14
ALTERNATOR................................................................................................................. 15
ALTERNATOR BELT....................................................................................................... 16
PEDAL LEVER ASSEMBLY............................................................................................. 17
POWER MODULE ASSEMBLY....................................................................................... 18
CRANK SHAFT PULLEY ASSEMBLY ............................................................................. 19
INTERMEDIATE PULLEY ASSEMBLY............................................................................ 20
SECTION IV
ELECTRONICS OVERVIEW AND WIRING BLOCK DIAGRAMS
DISPLAY CONSOLE BOARD (DSP HEART RATE PCB)................................................ 2
DISPLAY CONSOLE BOARD (INTEGRATED PCB)........................................................ 4
ALTERNATOR CONTROL BOARD ................................................................................. 6
ALTERNATOR................................................................................................................. 7
WIRING BLOCK DIAGRAM FOR DSP HEART RATE BOARD........................................ 8
WIRING BLOCK DIAGRAM FOR INTEGRATED PCB..................................................... 9
NOTES............................................................................................................................ 10
SECTION V
PARTS IDENTIFICATION
MODEL ID AND SN LOCATION...................................................................................... 2
GK53-00012-XXXX SN 669724 - UP................................................................................ 3
GK53-00014-XXXX SN 665000 - 669723 ......................................................................... 5
GK53-00013-XXXX SN 685000 - UP................................................................................ 7
CT95-0XXX-18 SN 693097 - UP....................................................................................... 9
NOTES............................................................................................................................ 11
SECTION VI
MISCELLANEOUS INFORMATION
PREVENTIVE MAINTENANCE TIPS............................................................................... 2
UNPACKING INSTRUCTIONS ........................................................................................ 3
COMMUNICATING BY FAX............................................................................................. 4
FAX FORM...................................................................................................................... 5
NOTES............................................................................................................................ 6

© 2000 Life Fitness, a division of Brunswick Corporation. All rights reserved. All rights reserved. Life Fitness, Lifecycle, Lifepulse and Flexdeck are registered
trademarks, and Heart Rate Zone Training, Lifespring and RELY ON IT are trademarks of Brunswick Corporation. Polar is a registered trademark of Polar. Any
use of these trademarks, without the express written consent of Life Fitness or the corresponding companies is forbidden.
M051-00K53-B011
11-2000

1
Life Fitness Model 9500 Series Cross-Trainers
SECTION I
TROUBLESHOOTING
GUIDES
Section I

2
Life Fitness Model 9500 Series Cross-Trainers
Malfunction Probable Cause Corrective Action
Loud thumping noise when
pedal levers rotate under load. Pulleys misaligned. Loosen the pillow block bearing, align the pulleys and then retighten the pillow block
bearings.
Rubbing/whining noise when
pulleys are rotating. Dirt build up in pedal rails. Clean and remove dirt build up.
Rear roller wheels frozen. Clean and lubricate with non detergent oil.
Link or Pedal Lever is
contacting heatshield. Reposition heat shield or replace.
Metal noise on rotation. Faulty intermediate shaft
assembly. Replace intermediate shaft assembly.
Grinding. Faulty pillow block. Replace pilow blocks on crankshaft.
Alternator. Relieve tension on alternator, spin flywheel for
smoothness. If thumping occurs, faulty
alternator. Replace alternator.
Rubbing/squeaking. Bearings at pivot points out of
position or dirty. Clean all sleeves in the linkage pivot areas and lubricate with non detergent oil.
Knock/thumping occurs 180°
apart in rotation. Setscrews in crank arm assembly are loose. Loosen setscrew and clamping screw in crank arm assembly. Place blue Locktite®(242) on
screws. Tighten setscrew first to set keyway,
then tighten clamping screw.
Small extension arm bolt
loose. Replace small extension arm kit.
Link or Pedal Lever is
contacting the heat shield. Reposition or replace the heat shield.
Drive Belt slipping. Loose or worn drive belt. Adjust the tension on the idler pulley tension
bolt of the U-Tension Bracket (See How To...).
Rotate pulley and check the tension. Belt
tension should be 170 FT LBS for new belt and
160 FT LBS if installing existing belt. If a J10
belt gauge is not available. Adjust to a 1/4”
(7mm) deflection.
Upper Arms slip. Bolts that connect the upper
and lower arms is loose. Adjust and tighten to a torque of 105 FT. LBS.

3
Life Fitness Model 9500 Series Cross-Trainers
Malfunction Probable Cause Corrective Action
Front to back play in pedal /
arm. Worn bearings. Check for front to back movement in bearings that connect pedal lever and crank arm or in
the 14” link.
Replace linkage bearing assembly.
Poly-V pulley on intermediate
shaft is loose. Replace intermediate shaft assembly (See How To...).
Crank Arm is loose. Loosen set screws and clamping screw in
Crank arm Assembly. Place blue Locktite®242
on screws. Tighten set screws first and then
tighten the clamping screw.
Alternator belt slipping. Loose or worn alternator belt Inspect for damage: replace alternator belt if
necessary. Adjust tension (See How To...).
Verify unit is turned on. Turn on at the ON/OFF switch.
Line cord damaged. Inspect AC line cord, verify no damage.
Damaged cable. Inspect all cables for damage.
Circuit breaker blown. Reset circuit breakers. Replace if needed.
Fuse on control board is blown. Replace control board.
Faulty entry module. Using a voltmeter, verify 14 v AC is at J4 on the
power control board.
Replace entry module.
No Power.
Faulty power control board. Using a voltmeter, verify 8 V DC at J1 pin 4 and
7 (see wiring diagram).
Cable connection. Disconnect and reconnect display console
cable connection
Pinched cable in RT/LT side. Remove shroud caps and inspect cables.
Replace damaged cable.
Inspect cable to make sure the right side cable
is on the users right, and the left is on the left
side.
Not reading heart rate.
Not communicating with DSP
board. Enter diagnostic, see if DSP and monitor version are displayed. If not displayed, replace
DSP board.
Section I

4
Life Fitness Model 9500 Series Cross-Trainers
Malfunction Probable Cause Corrective Action
Erratic heart rate. User’s hands are not making
proper contact.
Verify hands are contacting entire sensors.
Sweat is causing hands to slip Wipe hands and sensors.
Bad connection. Sensor loose or falling off. Replace Life Pulse
digital sensor with kit.
Remove handlebar shroud caps and verify cable
connection.
Cross talk from telemetry
receiver. Verify position of Cross-Trainer is proper distance from other telemetry equipped
equipment. See installation instructions or
operation manual.
Turn telemetry off from diagnostics and test Life
Pulse sensor separately.
Check for corrosion on connectors. Disconnect
and connect telemetry receiver.
Call Customer Support Service.
No LED. Cable connection. Remove display console and verify cable is
properly plugged into console.
8 vdc supply for LED. Using a voltmeter, measure for 8 vdc at console
cable connection. See wiring diagram for pin
configuration.
8 vdc supply not present at
cable. Using, measure for 8 vdc at power control board connection, J1. See wiring diagram pin
configuration.
No 8 vdc at J1. Faulty power control board. Replace power
control board.
No RPM. Unit shuts off one
minute into program. Bad cable connection. Verify cables connections at console to PCB (J1), and PCB to alternator (J2). Disconnect
and re-connect cables.
Using a voltmeter, verify cable continuity on
console to PCB and PCB to alternator.