Life Fitness 95L User manual

Models 95L, 95LWEZ, and 95LE
Summit Trainers
Customer Support Services
SERVICE MANUAL

Models 95L, 95LWEZ, and 95LE Summit Trainers
Table of Contents
1
TABLE OF CONTENTS
INTRODUCTION ......................................................................................................5
USING THIS MANUAL.............................................................................................7
CONTACTING CUSTOMER SUPPORT ...........................................................................9
THEORY OF OPERATION ...................................................................................... 11
TERMINOLOGY.................................................................................................. 13
TROUBLESHOOTING ............................................................................................... 15
Noisy operation ............................................................................................ 17
Burning odor ................................................................................................ 17
Pedals locked ............................................................................................... 17
Pedals resting on floor .................................................................................... 17
Slow pedal return.......................................................................................... 17
No power .................................................................................................... 18
Battery runs down ......................................................................................... 18
Console DOES NOT illuminate............................................................................ 19
Console dim................................................................................................. 20
Console illuminates then goes dark..................................................................... 20
Heart rate inoperative .................................................................................... 21
Lifepulse sensors loose.................................................................................... 21
Erratic heart rate display................................................................................. 21
Telemetry inoperative .................................................................................... 21
Unit pauses unexpectedly ................................................................................ 22
Inaccurate step activity display ......................................................................... 22
Load resistance varies during operation ............................................................... 22
Load resistance varies during operation, continued ................................................. 23
Unable to change audio level ............................................................................ 23
No audio to headphones .................................................................................. 23
Unable to receive stations when using cable.......................................................... 23
TV picture has “snow-like” appearance ............................................................... 23
LCD screen illuminated but blank ....................................................................... 24
LCD screen is dark ......................................................................................... 24
Screen DOES NOT respond to touch..................................................................... 24
Erratic touchscreen operation ........................................................................... 24
LED DIAGNOSTICS ................................................................................................. 25
95L DISPLAY CONSOLE ........................................................................................ 27
95LWEZ DISPLAY CONSOLE ................................................................................... 28
95LE DISPLAY CONSOLE....................................................................................... 29
DIAGNOSTICS MAP ............................................................................................. 30
ENTRY LEVEL ................................................................................................... 31
TEST/SERVICE – ALL LEDS AND KEYPAD TEST ............................................................. 32
TEST/SERVICE – WALKING LED TEST ........................................................................ 33
TEST/SERVICE – MISCELLANEOUS TEST 1................................................................... 34
TEST/SERVICE – MISCELLANEOUS TEST 2................................................................... 35
TEST/SERVICE – PORT I-O TEST.............................................................................. 36
TEST/SERVICE – LIFEPULSE TEST ............................................................................ 37
TEST/SERVICE – CSAFE NETWORK TEST .................................................................... 38
TEST/SERVICE – EEPROM TEST............................................................................... 39
TEST/SERVICE – TELEMETRY ENABLE/DISABLE ............................................................ 40
TEST/SERVICE – SYSTEM BEEPS ON/OFF ................................................................... 41
TEST/SERVICE – EZ KEYPAD NO/YES ........................................................................ 42

Models 95L, 95LWEZ, and 95LE Summit Trainers
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TABLE OF CONTENTS
LED DIAGNOSTICS - CONTINUED
TEST/SERVICE – LANGUAGE .................................................................................. 43
TEST/SERVICE – MAX PROGRAM DURATION ................................................................ 44
TEST/SERVICE – ENGLISH/METRIC UNITS................................................................... 45
TEST/SERVICE – WATTS DISPLAY ENABLE/DISABLE ....................................................... 46
TEST/SERVICE – METS DISPLAY ENABLE/DISABLE ......................................................... 47
TEST/SERVICE – CAL/HR DISPLAY ENABLE/DISABLE ...................................................... 48
TEST/SERVICE – TOTAL HOURS AND STATISTICS .......................................................... 49
TEST/SERVICE – ENTERTAINMENT CONTROLS ON/OFF................................................... 50
TEST/SERVICE – LANGUAGE SELECT ON/OFF.............................................................. 51
TEST/SERVICE – PHOTO SHOOT.............................................................................. 52
LCD DIAGNOSTICS ................................................................................................. 53
WELCOME SCREEN ............................................................................................. 55
WORKOUT SELECTION SCREEN............................................................................... 56
SYSTEMS OPTIONS – MAIN MENU ............................................................................. 57
SYSTEM TEST MENU............................................................................................ 58
SYSTEM DIAGNOSTICS ......................................................................................... 59
TEST ENGINEERING ............................................................................................ 60
TELEMETRY TEST .............................................................................................. 61
LIFEPULSE TEST ................................................................................................ 62
CSAFE NETWORK TEST ........................................................................................ 63
EEPROM TEST................................................................................................... 64
INFORMATION MENU........................................................................................... 65
INFORMATION STATISTICS .................................................................................... 66
SOFTWARE VERSIONS.......................................................................................... 67
SYSTEM ERRORS ................................................................................................ 68
USAGE LOG REPORT ........................................................................................... 69
CONFIGURATION MENU ....................................................................................... 70
MANAGER’S CONFIGURATION ................................................................................ 71
CUSTOM MESSAGE SETUP ..................................................................................... 72
MANUFACTURER’S CONFIGURATION MENU ................................................................ 73
TV SETUP........................................................................................................ 74
MAX VOLUME SETUP ........................................................................................... 75
TOUCHSCREEN CONFIGURATION ............................................................................ 78
HOW TO… SERVICE AND REPAIR GUIDES ....................................................................... 77
HOW TO… REPLACE THE CONSOLE SUPPORT COVER..................................................... 79
HOW TO… REPLACE THE CONSOLE ASSEMBLY............................................................. 80
HOW TO… REPLACE THE ACCESSORY TRAY................................................................ 81
HOW TO… REPLACE THE CONSOLE SUPPORT BRACKET .................................................. 82
HOW TO… REPLACE THE OUTER DEADSHAFT COVERS ................................................... 83
HOW TO… REPLACE THE HANDLEBAR WITH GRIP......................................................... 84
HOW TO… REPLACE THE LIFEPULSE SENSORS ............................................................. 85
HOW TO… REPLACE THE MAIN SHROUDS ................................................................... 86
HOW TO… REPLACE THE LOWER TRACK COVER........................................................... 87
HOW TO… REPLACE THE HANDRAIL ASSEMBLY............................................................ 88
HOW TO… REPLACE THE CONSOLE CABLE ASSEMBLY .................................................... 89
HOW TO… REPLACE THE REAR STEP ASSEMBLY ........................................................... 91
HOW TO… REPLACE THE ROCKER ARM COVER ............................................................ 92
HOW TO… REPLACE THE LEVER JOINT ASSEMBLY ........................................................ 93
HOW TO… REPLACE THE RIGHT AND LEFT CLEVIS COVER ASSEMBLIES ................................ 94

Models 95L, 95LWEZ, and 95LE Summit Trainers
Table of Contents
3
TABLE OF CONTENTS
HOW TO… SERVICE AND REPAIR GUIDES - CONTINUED
HOW TO… REPLACE THE MONOCOLUMN ................................................................... 95
HOW TO… REPLACE THE ROCKER ARM ..................................................................... 96
HOW TO… REPLACE THE PEDAL ............................................................................. 97
HOW TO… REPLACE THE PEDAL TRACK COVER............................................................ 98
HOW TO… REPLACE THE PEDAL TRUCK ASSEMBLY ....................................................... 99
HOW TO… REPLACE THE CONTROL LINK ASSEMBLY .....................................................102
HOW TO… REPLACE THE WHEELS ..........................................................................103
HOW TO… REPLACE THE UPPER BELT .....................................................................104
HOW TO… REPLACE THE LOWER BELT.....................................................................106
HOW TO… REPLACE THE 6V BATTERY .....................................................................107
HOW TO… REPLACE THE POWER CONTROL BOARD......................................................108
HOW TO… REPLACE THE FLEXONIC BELTS ................................................................109
HOW TO… REPLACE THE POLY-V PULLEYS ................................................................110
HOW TO… REPLACE THE CLUTCH PULLEY ASSEMBLY ...................................................111
HOW TO… REPLACE THE ALTERNATOR ....................................................................112
HOW TO… REPLACE THE SPRINGS ..........................................................................113
HOW TO… REPLACE THE RESISTOR BRACKET ASSEMBLY................................................114
HOW TO… REPLACE THE REED SWITCH AND BRACKET ASSEMBLY .....................................115
HOW TO… REPLACE THE CLUTCH SPROCKETS............................................................116
HOW TO… REPLACE THE CLUTCH SHAFT BEARING HOUSING ..........................................118
ELECTRONICS .....................................................................................................121
WIRING BLOCK DIAGRAM – MODEL 95L AND 95LWEZ ....................................................123
WIRING BLOCK DIAGRAM – MODEL 95LE ...................................................................124
INDEX...............................................................................................................125

Models 95L, 95LWEZ, and 95LE Summit Trainers
Table of Contents
4

Models 95L, 95LWEZ, and 95LE Summit Trainers
INTRODUCTION

Models 95L, 95LWEZ, and 95LE Summit Trainers
Using this Manual
7
USING THIS MANUAL
This service manual is applicable to Life Fitness Models 95L, 95LWEZ, and 95LE
Summit Trainers. Information in this manual represents typical configurations and
may differ slightly from actual equipment. The manual provides recommendations
for safe and efficient approaches to service situations.
This manual is arranged in these sections:
TABLE OF CONTENTS
INTRODUCTION
TROUBLESHOOTING & DIAGNOSTICS
“HOW TO...” SERVICE AND REPAIR GUIDES
ELECTRONICS
INDEX
Refer to the table of contents for section subtopics.
When an operating problem occurs, attempt to isolate the cause by referring to
the troubleshooting guides and diagnostic tests. When applicable, symptoms are
listed in these guides with tests and probable causes.
Once you have pinpointed the source of the problem, refer to the “How To…”
guides for recommended repair procedures. The “How To…” guides are organized
by replaceable part or assembly name. For convenience, each guide lists the tools
required to complete each repair.
Before installing a part, read the entire "How To..." section and follow the
recommended step-by-step procedures. This will ensure a safe and efficient
installation.

Models 95L, 95LWEZ, and 95LE Summit Trainers
Using This Manual
8

Models 95L, 95LWEZ, and 95LE Summit Trainers
Contacting Customer Support
9
CONTACTING CUSTOMER SUPPORT
To speed Life Fitness Customer Support Service’s response, please be prepared to
provide the following information to the phone technician:
Model number
Serial number (a 3-letter, 6-number sequence)
Symptom of problem
Phone technicians are available Monday through Friday from 8:00 AM to 5:00 PM
(Central time). Fax numbers are active 24 hours a day, 7 days a week.
LIFE FITNESS - CUSTOMER SUPPORT SERVICES
5100 River Road, Schiller Park IL 60176; U.S.A.
Telephone: [phone] or toll free [phone]
Fax: [phone] or toll free [phone]
Location of Model
and Serial Number
s

Models 95L, 95LWEZ, and 95LE Summit Trainers
Contacting Customer Support
10

Models 95L, 95LWEZ, and 95LE Summit Trainers
Theory of Operation
11
THEORY OF OPERATION
The electronic system on the Summit Trainer consists of four main functional
blocks: 1) the console, 2) HR (heart rate) telemetry, and 3) the alternator, power
control board, and load, and 4) Lifepulse™ contact HR. The following is a
description of each block:
CONSOLE
The system voltage (6-7.5Vdc) enters on connector P2 pin 3 and is used to power
the LEDs and provide a supply voltage for the 5V-regulator circuitry used to power
the microprocessor section. The keypad entry (user input), Lifepulse, and
telemetry are all managed by the microprocessor. The console sends a PWM signal
to the power control board to control the duty cycle of the load.
HR TELEMETRY
HR Telemetry is implemented via a Polar®receiver located in the monocolumn
cover at the front of the unit. The Polar receiver connects to the console at
connector P7.
ALTERNATOR, POWER CONTROL BOARD, AND LOAD
Using the PWM signal from the console, the power control board switches the
current on and off at the load via Q1. The control board also regulates the
alternator voltage using the U1. Q3 and Q9 are used to sense the reed switch
actuation (“autostart” feature).
LIFEPULSE
The bullhorn electrodes connect to the console board at connector P4. Pins 3 and 4
are signal, pins 1 and 2 are ground.

Models 95L, 95LWEZ, and 95LE Summit Trainers
Theory of Operation
12

Models 95L, 95LWEZ, and 95LE Summit Trainers
Terminology
13
TERMINOLOGY
The following words and acronyms are used throughout this manual. Take time to
familiarize yourself with them.
Term Definition
connectors Plugs and sockets used to link wires and components in
electrical circuits
CSAFE Communication specification for fitness equipment
EEPROM Electrically Erasable Programmable Read-Only Memory
EEROM Electrically Erasable Read-Only Memory
LCD Liquid Crystal Display
LDC Load Duty Cycle
LED Light Emitting Diode; used to show a state of operation
Lifepulse™
System used to simulate a user’s heart rate; detects
electrical impulses in the hands, digitizes them and
processes the signal using a digital signal processor
MET Metabolic Equivalent; the expression of the rate of
work (power output) for the human body at rest
PCB Power Control Board; regulates voltage to the
alternator, console, and battery
Polar®receiver
A device directly in front of the user which monitors
heart rate via radio frequencies transmitted by the
chest strap
PWM Pulse Width Modulation
reed switch An electronic device that measures RPMs by sensing a
magnet with each revolution of the flywheel
RPM Revolutions Per Minute
Vsys System voltage
Watt The expression of a device’s mechanical rate of work
(power output)

Models 95L, 95LWEZ, and 95LE Summit Trainers
Terminology
14

Models 95L, 95LWEZ, and 95LE Summit Trainers
TROUBLESHOOTING

Models 95L, 95LWEZ, and 95LE Summit Trainers
Troubleshooting
17
TROUBLESHOOTING
Symptom Probable Causes Corrective Actions
Clutch shaft bearings
worn excessively
Replace bearing housing assembly.
Clutch pulley bearings
worn excessively
Inspect clutch pulley bearings for
excessive wear or binding. Replace
clutch pulley and bearings.
Alternator bearings worn
excessively
Remove alternator and drive belts.
Spin alternator flywheel and
listen/feel for roughness. Replace
alternator.
Pedal roller bearings worn
excessively
Inspect all roller bearings for
excessive wear or binding. Replace
rollers.
Flexonic belt contami-
nated or excessively worn
Clean or replace belt.
Space between Rocker
Arm and Collar exceeds
.005”
Adjust and tighten collar so that
gap between collar and rocker arm
is .005”
Noisy operation
Timing belt assembly
worn excessively
Replace belt.
Burning odor New machine A new Summit Trainer may emit a
slight odor during the first few
hours of operation as the load
resistor heats up for the first few
times. If the odor persists, contact
Customer Service.
Defective clutch sprocket
assembly
Replace clutch sprocket assemblyPedals locked/unable to move
pedals
Foreign object lodged in
pedal track
Inspect pedal tracks for foreign
objects
Pedals resting on floor Upper timing belt broken Replace upper timing belt
Pedal roller bearings worn
excessively
Replace rollers.
Belt assembly or belt
pulley binding
Replace pulley and/or belt.
Slow pedal return
Clutches binding Check clutch operation to make
sure there is no binding in the
free-spinning direction. Replace
clutch.

Models 95L, 95LWEZ, and 95LE Summit Trainers
Troubleshooting
18
TROUBLESHOOTING
Symptom Probable Causes Corrective Actions
Faulty battery Verify battery pack voltage is
at least 6.3 VDC. Replace
battery pack.
Faulty reed switch Position magnet away from
reed switch. Verify continuity
between pins #2 and #3. Verify
an open connection between
pins #1 and #3. Reposition
magnet close to reed switch.
Verify an open circuit between
pins #2 and #3, and continuity
between pins #1 and #3.
Replace reed switch.
No power
Reed switch improperly
positioned
Verify that reed switch is in
correct position.
Stepping rate extremely slow Increase step rate.Battery runs down
Summit Trainer is consistently
used by lighter (less than 120
lbs.) users and workout
durations are consistently less
than 20 minutes, or usage is
less than 2 hours per day
Charge unit overnight at least
once per week to ensure a long
life for the battery.