Life Fitness Exercise Bike Lifecycle 8500 User manual

Models 8500, 9100, and 9500HR
Total Body Cross-Trainers with Rear Drive System
Customer Support Services
SERVICE MANUAL

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Cross-Trainer Models CT8500, CT9100, and CT9500HR. Note: Information represents
typical configuration and may differ slightly from actual equipment. The Service Manual provides recommendations for
safe and efficient approaches to problem situations. This manual is separated into six sections.
INTRODUCTION
THEORY OF OPERATION
TERMINOLOGY
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
Refer toTABLE OF CONTENTS for section topics.
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 7:00 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 consists of 3 letters and 6 numbers
3. Symptom of problem
4. Part name and number to order (if known)
Before installing a part, review "How To..." and follow the step by step procedures recommended to install the part safely and
efficiently. If you have questions or comments, please telephone, FAX or write us. We are:
LIFE FITNESS - CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue; Franklin Park, IL 60131; U.S.A.
Telephone: [phone] or Toll Free 800.351.3737
FAX: [phone] or Toll Free 800.216.8893

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
THEORY OF OPERATION
The electronic system on the rear-drive crosstrainer is made up of three main functional blocks: 1) Console, 2) HR
telemetry, and 3) Alternator, Power Control Board, and Load. In addition, the 9500 model has Lifepulse contact HR.
The following is a description of each functional block:
CONSOLE
The system voltage (6-7.5Vdc) enters on connector P2 pin 1 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’s input), Lifepulse (9500HR only), and Telemetry are all processed by the microprocessor.
The console outputs a PWM signal to the power control board to control the duty cycle of the load.
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 comparitors. Q3 and Q9 are used to
sense the reed switch actuation (autostart feature).
POLAR
HR telemetry is implemented via a Polar receiver located in the rocker arm shroud at the front of the unit. The
Polar receiver connects to the console at connector P7.
LIFEPULSE (9500 ONLY)
The handlebar electrodes connect to the console board at connector P9. Pins 1 and 4 are signal, pins 2 and 3 are
circuit reference.

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
TERMINOLOGY
The following words and acronyms are commonly referred to throughout this manual. Take time to familiarize yourself
with them.
Connectors Electrical plugs used to connect wiring into electrical component.
Display Console
Board Electronic board for making settings and monitoring physical output.
DSP Disgital system processing.
EEPROM Electrically errasible programmable read only memory.
EEROM Electrically errasible read only memory.
LDC Load duty cycle.
LED Light emitting diode used to show a state of operation.
LifePulse Heart rate sensors on hand grips.
PCB Power control board regulates voltage to alternator, console, and battery.
Polar Receiver A device directly in front of the operator that monitors heart rate.
Rear drive The area where all the drive components reside.
RPM Revolutions per minute describes the amount of times something turns within a minute of
time.

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
TABLE OF CONTENTS
SECTION I
TROUBLESHOOTING GUIDES PAGE
GRINDING, RUBBING, KNOCKING NOISE..................................................................... 2
DRIVE BELT SLIPPING ................................................................................................ 3
UPPER ARMS LOOSE................................................................................................. 3
PLAY IN PEDAL LEVER............................................................................................... 3
NO LOAD.................................................................................................................... 3
NO LEDS ON DISPLAY................................................................................................ 3
ALTERNATOR BELT SLIPPING..................................................................................... 4
NO HEART RATE OR ERRATIC HEART RATE ............................................................... 4
NO LEDS or RANDOM LEDS LIT................................................................................... 5
NO RPM...................................................................................................................... 5
AUTO START FAILURE ................................................................................................ 5
NOTES........................................................................................................................ 6
SECTION II
DIAGNOSTIC MODES
DISPLAY CONSOLES.................................................................................................. 2
ENTERING DIAGNOSTIC STATES 1-17 ......................................................................... 3
DIAGNOSTIC STATE 1: LEDS AND KEYPAD TEST........................................................ 4
DIAGNOSTIC STATE 2: INDIVIDUAL LED TEST.............................................................. 5
DIAGNOSTIC STATE 3: CODE VERSION/RPM/HEART RATE/LDC TESTS....................... 6
DIAGNOSTIC STATE 3: CODE VERSION/RPM/NETWORKING/LDC TESTS
(DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 7
DIAGNOSTIC STATE 4: FIELD/ALTERNATOR – REGULATOR TEST................................ 8
DIAGNOSTIC STATE 5: PROGRAM VERSION AND NETWORKING TEST....................... 9
DIAGNOSTIC STATE 5: LIFEPULSE TEST
(DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 10
DIAGNOSTIC STATE 6: MAXIMUM WORKOUT DURATION............................................. 11
DIAGNOSTIC STATE 7: TELEMETRY ON/OFF............................................................... 12
DIAGNOSTIC STATE 8: ENGLISH / METRIC UNITS ........................................................ 13
DIAGNOSTIC STATE 9: POWER SUPPLY TYPE ........................................................... 14
DIAGNOSTIC STATE 10: SHUTDOWN TIME .................................................................. 15
DIAGNOSTIC STATE 11: PROGRAM TIME .................................................................... 16
DIAGNOSTIC STATE 12: STATISTICS............................................................................ 17
DIAGNOSTIC STATE 13: METS ENABLE / DISABLE...................................................... 18
DIAGNOSTIC STATE 14: KEYPAD SELECTION............................................................. 19
DIAGNOSTIC STATE 15: TOGGLE ENABLE / DISABLE.................................................. 20
DIAGNOSTIC STATE 16: PHOTOSHOOT....................................................................... 21
DIAGNOSTIC STATE 16: LANQUAGE CONFIGURATION
(DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 22
DIAGNOSTIC STATE 17: PHOTOSHOOT
(DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 23
NOTES........................................................................................................................ 24

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
TABLE OF CONTENTS – Continued
SECTION III
HOW TO...REPLACE THE:
DISPLAY CONSOLE .................................................................................................... 2
ACCESSORY TRAY (OPTIONAL ON CT8500)................................................................ 3
DISPLAY CONSOLE SUPPORT ASSEMBLY................................................................. 4
REAR COVERS ........................................................................................................... 5
CRANKARM ROLLER ASSEMBLY AND COVER........................................................... 6
CRANKARM ASSEMBLY ............................................................................................. 7
DRIVE BELT AND ALTERNATOR BELT......................................................................... 8
POWER CONTROL BOARD ASSEMBLY....................................................................... 9
ALTERNATOR.............................................................................................................. 10
ALTERNATOR BELT..................................................................................................... 11
PEDAL LEVER ASSEMBLY ......................................................................................... 12
ROCKER ARMS........................................................................................................... 13
TIE ROD...................................................................................................................... 14
CRANKSHAFT PULLEY ASSEMBLY............................................................................. 15
INTERMEDIATE PULLEY.............................................................................................. 16
LOAD RESISTORS....................................................................................................... 17
USER ARMS ............................................................................................................... 18
POLAR RECEIVER...................................................................................................... 19
MONOCOLUMN COVER............................................................................................... 20
FRAME COVER........................................................................................................... 21
FRONT COVER............................................................................................................ 22
BATTERY .................................................................................................................... 23
REAR WHEELS AND AXLE .......................................................................................... 24
ENDCAPS................................................................................................................... 25
PEDAL ....................................................................................................................... 26
SET JUMPERS ON CSAFE CARD ................................................................................ 27
NOTES........................................................................................................................ 28
SECTION IV
ELECTRONICS OVERVIEW / WIRING DIAGRAM
DISPLAY CONSOLE BOARD........................................................................................ 2
POWER CONTROL BOARD.......................................................................................... 4
ALTERNATOR.............................................................................................................. 5
WIRING BLOCK DIAGRAM........................................................................................... 6
NOTES........................................................................................................................ 7

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
TABLE OF CONTENTS – Continued
SECTION V
PARTS IDENTIFICATION
MODEL IDENTIFICATION and SERIAL NUMBER LOCATION........................................... 2
CT 8500....................................................................................................................... 3
CT 9100....................................................................................................................... 5
CT 9500 - 15 ................................................................................................................ 7
CT 9500 - 17 ................................................................................................................ 9
NOTES........................................................................................................................ 11
SECTION VI
MISCELLANEOUS INFORMATION
PREVENTIVE MAINTENANCE TIPS.............................................................................. 2
INSTALLATION INSTRUCTIONS .................................................................................... 3
UNPACKING INSTRUCTIONS........................................................................................ 9
COMMUNICATING BY FAX........................................................................................... 10
NOTES........................................................................................................................ 12

© 2000 Life Fitness, a division of Brunswick Corporation. All rights reserved. Life Fitness, Lifecycle, and Lifepulse are registered trademarks, and Heart
Rate Zone Training and RELY ON IT are trademarks of Brunswick Corporation. Polar is a registered trademark of Polar Electro, Inc.
Any use of these trademarks without the express written consent of Life Fitness or the corresponding companies is forbidden.
M051-00K61-B014
07/00

1
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
SECTION I
TROUBLESHOOTING
GUIDES
Section I

2
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
Malfunction Probable Cause Corrective Action
Grinding, rubbing, knocking noises
when pedal levers rotate under
load.
Pulleys misaligned. Loosen the pillow block bearings,
realign the pulleys, and retighten the
pillow block bearings.
Dirt build up in pedal tracks. Clean and remove dirt build up.
Rear roller wheels frozen. Clean and lubricate with non
detergent oil.
Link cover contacting rear cover. Reposition rear cover(s) or replace.
Check that the inner link cover
mounting screws are properly
installed.
Make sure no weld interference
occurs between the crankarm and
the disk cover.
Excessive disk wobble.
Ensure that the crankshaft is flush
with the crankarm and check for
proper alignment. See How To.
Faulty intermediate shaft assembly. Replace intermediate shaft assy.
Faulty pillow block. Replace pillow blocks on crankshaft.
Alternator. Relieve tension on alternator, spin
flywheel for smoothness. If
thumping occurs, faulty alternator.
Replace alternator.
Bearings at pivot points are out of
position or dirty. Clean all sleeves in the linkage pivot areas and lubricate with non
detergent oil.
Setscrews or crankarm bolt in
crankarm assembly are loose. Loosen setscrew and clamping screw in crankarm assembly. Apply
blue Loctite®(242) on screw threads.
Tighten setscrew first to set keyway,
then tighten clamping screw.
Crankarm bolt requires no Loctite.
Small extension arm bolt loose. Replace small extension arm kit.
Faulty link bearings. Replace link assembly.

3
Link mounting loose. Clean, lubricate, and retighten.

4
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
Malfunction Probable Cause Corrective Action
Grinding, rubbing, knocking noises
when pedal levers rotate under
load.
Excessive end play in rocker arms. Adjust collars as necessary to take
out the end play. See How To
Replace Rocker Arms.
Pedal lever vibrates or squeaks during
operation. Align pedal lever. See How To Replace Pedal Lever.
Pedal tape not adhering properly. See How To Replace Pedal Lever
Drive Belt slipping. Loose or worn belt. Check belt tension using a J10 belt
gauge. The belt deflection should be
1/4’ (7mm) at 170 lb for a new belt
and 160 lb for an existing belt.
Upper Arms feel loose. Bolts that connect the upper and
lower arms are loose. Adjust and tighten to a torque of 30- 35 ft lb.
Front to back play in pedal lever. Worn bearings. Check for front to back movement in
bearings that connect pedal lever to
the rocker arm. Replace pedal lever
assembly.
Poly V-Pulley on intermediate shaft is
loose. Replace intermediate shaft assembly.
Crankarm loose. Loosen setscrews and clamping
screw in Crankarm Assembly. Apply
blue Loctite®242 on screws. Tighten
setscrews first and then tighten the
clamping screw.
Worn link bearings. Replace link.
Loose link mounting. Clean, lube, and reassemble.
No Load. Faulty cables, power console board,
or alternator. Enter diagnostic state 3 and execute the field duty cycle and increase the
load. If load does not increase,
replace alternator.
No LEDs on display. Faulty display console. Using a voltmeter, verify 8Vdc at the
10 position Molex connector pin 1 on
the display console PCB. If voltage
is present, replace display console.
If not, replace power control board.
Section I

5
Faulty power control board. Using a voltmeter, verify 8Vdc at 11
position connector pin 4 on the
power control board. If present,
replace console cable. If not, replace
board.

6
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
Malfunction Probable Cause Corrective Action
Alternator belt slipping. Belt is loose. Retension from 65-70 lb.
No heart rate or erratic heart rate. Pinched cable in Monocolumn cover. Remove monocolumn covers and
inspect cables. Replace damaged
cable.
Defective chest strap or improperly
positioned. Replace chest strap or reposition it. Reset transmitter. Refer to
Diagnostics state 3 to execute the
heart rate test.
No heart rate reading. Execute Diagnostic Mode to verify
performance of heart rate function.
Faulty cable connection. Verify heart-rate cable is properly
connected. Using an ohmmeter,
verify continuity at the main console
cable.
Malfunctioning user arm/Lifepulse
(CT9500HR) Grip Assembly (include
worn or damaged heart rate lead).
Replace user arm/Lifepulse
(CT9500HR) Assembly.
Life Pulse user arm defective. Verify user arm is functioning. Wipe
sensors dry. Using an ohmmeter,
verify continuity between Lifepulse
sensor and cable connection.
Replace if defective.
Loose or malfunctioning heart rate
lead connection at Display Console. Secure connection. Replace malfunctioning user arm/Lifepulse
(CT9500HR) Grip Assembly.
Heart-rate (DSP) Board (CT9500HR)
is faulty or not communicating. Verify that the heart-rate (DSP) board (CT9500HR) is communi-
cating. If defective, replace.
Malfunctioning Display Console. Test with known good Display
Console. Replace malfunctioning
Display Console.
Cross talk from telemetry and another
transmitter or possible interference
from other electronic devices.
Position Cross-Trainer at least 3 ft
(1 m) from unit with telemetry or from
other electronic devices.
Bad connection. Check for corrosion on connectors.
Disconnect and reconnect telemetry
receiver.

7

8
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
Malfunction Probable Cause Corrective Action
No LEDs or random LEDs lit. Cable connection faulty. Remove display console and verify
cable is properly plugged into
console.
Main wire harness damaged. Check for a damaged wire harness.
Replace wire harness.
No RPM. Unit shuts off one minute
into program. Bad cable connection. Verify cables connections at console to power control PCB, and power
control PCB to alternator.
Disconnect and reconnect cables.
Using a voltmeter, verify cable
continuity on console to power
control PCB and power control PCB
to alternator.
Auto start failure No RPM Operator must be pedling unit for the
auto start feature to activate.
Battery Battery voltage should be 5.8 – 6.3
Vdc. If not, replace the battery.
Bad cable connection. Verify cables connections at
console, board, and reed switch are
correct and connected properly.
Magnet Verify that magnet is on crank
pulley. If magnet is not present,
reinstall magnet.
Faulty reed switch or board. Perform a continuity test. Inspect
reed switch for damage. If
necessary, replace the board.
Dead battery after C-Safe card is
installed. Replace battery if under 5 VDC and reset jumpers in C-Safe card. See
How To Set Jumpers.
Section I

9
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
NOTES:

1
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
SECTION II
DIAGNOSTIC MODES
Section II

2
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
CT8500, CT9100, and CT9500HR Display Consoles
The following three(3) Display Consoles are representative for each model crosstrainer. The following Diagnostic State
pages depict a CT9100 Display Console. Regardless of Display Console, the Message Center always provides current
Diagnostic Data.
Section II
Display
Lock
Display
Lock
Display
Lock
ClearClear
Clear
EnterEnter
Enter
PausePause
Pause
Quick
Workout
Start
AGE
85%
60%
120
117
114
111
108
105
102
99 96 93
65%
80%
HEARTRATE
¨
Quick Start:
Press ‘Start’
Press ‘Quick Workout’
Level
Calories
Heart Rate
Distance
®
RPM
Time
179 170 162 153 145 136 128 119 111 102
10 20 30 40 50 60 70 80 90100
Life Fitness USA:
Life Fitness Intl.:
Life Fitness UK:
1-800-735-3867
([phone]
(+44) (0)1353 666017
CT8500
Display
Lock
Display
Lock
Display
Lock
ClearClear Clear
Aerobics
Mode
Aerobics
Mode
Aerobics
Mode Reverse Mode
PausePause Pause
Quick
Workout
Start
EnterEnterEnter
RPM Level Calories HeartRate Distance Cal/Hour WattsTime
AGE
85%
60%
120 117 114 111 108 105 102 99 96 93
65%
80%
HEARTRATE
¨
QuickStart:
Press ‘Start’
Press ‘Quick Workout’
®
179 170 162 153 145 136 128 119 111 102
10 20 30 40 50 60 70 80 90 100
Life Fitness USA:
Life Fitness Intl.:
Life Fitness UK:
1-800-735-3867
([phone]
(+44) (0)1353 666017
CT9100
CT9500HR (Display Lock Equipped) CT9500HR
123
456
789
0
Start
EnterEnterEnter
Aerobics
Mode Reverse Mode
Clear
Pause
Quick
Workout
Display
Lock
Level
Calories HeartRate Distance Cal/Hour WattsTime
AGE
179
85%
60%
170 162 153 145 136 128 119 111 102
120 117 114 111 108 105 102 99 96 93
65%
80%
HEARTRATE
QuickStart:
Press ‘Start’
Press ‘Quick Workout’
®
RPM
10 20 30 40 50 60 70 80 90 100
Life Fitness USA:
Life Fitness Intl.:
Life Fitness UK:
1-800-735-3867
([phone]
(+44) (0)1353 666017
Start
1
2
3
4
5
6
7
8
9
0
Start
Start
EnterEnter
Enter
Aerobics
Mode Reverse Mode
Clear
Pause
Quick
Workout
RPM
Level
Calories Heart Rate Distance Cal/Hour WattsTime
Life Fitness USA:
Life Fitness Intl.:
Life Fitness UK:
1-800-735-3867
([phone]
(+44) (0)1353 666017
AGE
179
85%
60%
170
162
153
145
136
128
119
111
102
120
117
114
111
108
105
102
99 96 93
65%
80%
HEARTRATE
Quick Start:
Press ‘Start’
Press ‘Quick Workout’
10 20 30 40 50 60 70 80 90
100

3
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
ENTERING DIAGNOSTIC STATES 1-17
To enter the diagnostic mode, proceed as follows:
1. Press down and hold the DOWN ARROW key. While doing this, press the CLEAR (CT9100) or CLEAR/PAUSE
(CT9500) key twice within 2.5 seconds. The console will go blank momentarily, but do not release the DOWN
ARROW key. As soon as the MESSAGE CENTER displays the word “DIAGNOSTICS,” then release the DOWN
ARROW key.
2. Press the ENTER key to scroll through diagnostic states 1-17.
3. Press the UP and DOWN ARROW keys to activate a selection within a diagnostic state.
4. Press the CLEAR key to scroll back to a previous diagnostic state
5. Press the CLEAR key as required to exit out of the diagnostic program.
6. For diagnostic states that have a subdirectory, press the DISPLAY LOCK key to enter.
NOTE: RPM diagnostic mode requires pedaling.
NOTE: Factory defaults are displayed when the LED is illuminated on the ENTER key.
Section II