Life Fitness Exercise Bike Lifecycle 9100 User manual

Lifecyc/~ 9100 and 9500HR
Belt Drive Series Exercise Bikes
Customer SU/1Porl Services
SERVICE MANUAL

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Lifecycle 9100 and 9500HR Series Exercise Bikes
INTRODUCTION
HOW TO USE SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Lifecycle Models 9100 and 9500HR (via Lifepulse™ digital and Pola
compatible telemetry heart rate monitoring systems) belt-drive exercise bikes. Information is appropriate to all
models unless otherwise noted.
Note: Information represents typical configuration and may differ slightly from actual equipment.
The Service Manual provides recommendations of safe and efficient approaches to problem situations. This
manual
is separated into five sections.
INTRODUCTION
THEORY OF OPERATION
TABLE OF CONTENTS
Section I
oTROUBLESHOOTING GUIDES
Section
II
oDIAGNOSTIC MODE
Section
III
o"How To .. ." SERVICE AND REPAIR GUIDES
Section IV
oELECTRONIC OVERVIEW
oWIRING BLOCK DIAGRAMS
Section V
oPARTS IDENTIFICATION
Section
VI
oMISCELLANEOUS INFORMATION
Refer to TABLE
OF CONTENTS for section topics.
When
an operating problem occurs, refer to trouble shooting guides and diagnostic mode to isolate cause. When
applicable, guides are listed by problem symptom followed with suggestions of probable cause(s) .
Once source of problem is identified, consult "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 specific function.
Refer to PARTS IDENTIFICATION to identify proper name and number of part to order for repair of equipment.
Areproducible FAX order claim form is given in COMMUNICATING BY TELEFACSIMILE for convenient ordering of
service parts.
To order, contact Life Fitness Customer Support Services.
Via FAX -24 hrs. /day, 7days/week.
Via telephone -Monday through Friday from 8:00
AM to 6:00 PM (CST).
Via
post· At address cited.
To speed Life Fitness Customer Support Services response to your needs, please provide the following information.
1. Model number
2. Serial number
3. Symptom of problem
4. Part name and number to order (if known)
Before installing part, review "How
To .. ." and follow step by step procedures recommended to install part safely and
efficiently.

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Lifecycle 9100 and 9500HR Series Exercise Bikes
THEORY OF OPERATION
The Lifecycles bikes are stationary exercise bicycles that provide ascientific method of improving body fitness and
endurance through its unique "12 or 24 MINUTE RIDE TO VIGOROUS HEALTH."
Computerized state-of-the-art electronics have been engineered to satisfy arange of personalized fitness needs of
the beginner to the needs of the most advanced fitness enthusiast.
The Lifecycle concept is based
on the self-motivational principle of INTERVAL TRAINING WITH PROGRESSIVE
OVERLOAD. During the HILL and RANDOM exercise programs, the workload against which you are pedaling is
periodically changed by the built-in computer resulting
in an automatic increase or decrease in pedal resistance.
This simulates riding up and down virtual "hills," which are visualized on the display console with columns of "lights"
that move from right to left.
With features like the RACE program, Fit Test, level 0resistance -almost 25% easier than the level 1found
on
earlier editions of the classic Lifecycle exercise bike -and exciting variable-ergonomic handlebars, you'll be much
more likely to stick with your exercise plan and accomplish your goals.
The ability to select aprogram to match your particular needs
is what distinguishes Lifecycle bikes as the world's
most popular physical conditioning device. Its user-flexibility means that you will never outgrow the innumerable
challenges the Lifecycle exercise bike has to offer.
The beginner starts with basic programs, then improves his level of fitness at his own rate while constantly
challenging himself to the next level. For well-conditioned individuals, the advanced programs offer more difficult
modes
of training. In fact, many world-class athletes use Lifecycle bikes to maintain peak levels of conditioning.
The Lifecycle bike is an extremely rugged exercise bicycle that is designed to withstand heavy use for many years.
During its two-year research and development phase, prototype Lifecycles were placed
in high-volume health clubs
and fitness centers across the United States where they were field tested for up to 18 hours aday.
If you have questions orcomments 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] Toll-free: 800.351.3737
FAX: [phone] Toll-free: 800.216.8893

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Lifecycle 9100 and 9500HR Series Exercise Bikes
TABLE OF CONTENTS
INTRODUCTION
Howto use this Service Manual
Theory of Operation
SECTION ITROUBLESHOOTING GUIDE PAGE
DISPLAY CONSOLE LEDS NOT ILLUMINATING 2
DISPLAY CONSOLE INITIALIZES THEN FAILS 2
NO PROMPT UPON RELEASE
OF START KEY 2
DISPLAY CONSOLE LEDS ARE NOT CONSTANT 3
DISPLAY CONSOLE LEDS DO NOT EXTINQUISH IN TIMELY MANNER 3
PROMPT PERSISTENTLY FLASHES 3
DISPLAY CONSOLE KEYS DO NOT FUNCTION 4
EXCESSIVE RESISTANCE LOAD AT START OF PROGRAM .4
EXCESSIVE RESISTANCE LOADING OCCURS DURING LOADING .4
DURING MANUAL PROGRAM RESISTANCE VARIES 5
DURING RANDOM OR HILL PROGRAMS RESISTANCE CONSTANT 5
PEDALING IS DIFFICULT 5
PEDALING
TO EASY 6
BATTERY OVER-HEATING 6
BIKE NOT STABLE 6
LOAD NOISE 7
NO HEART RATE 8
HANDLEBAR GRIPS LOOSENING 8
L1FEPULSE SENSOR MOLDING LOOSE 8
SECTION II DIAGNOSTIC MODES
DIAGNOSTICS STATE -Display Console Layout.. 2
DIAGNOSTICS STATE -How To Enter Diagnostic Modes 3
DIAGNOSTICS STATE 1 - ALL LEDS and KEYPAD TEST 4
DIAGNOSTICS STATE 2 - INDIVIDUAL LED TEST 5
DIAGNOSTICS STATE 3 - VERSION #: RPM, HR, and LOAD TESTS 6
DIAGNOSTICS STATE 3 - VERSION #: RPM, NETWORK STATUS, and LOAD TESTS
(LC9500HR Integrated PCB Only) 7
DIAGNOSTICS STATE 4 - L1FEPULSE and NETWORK STATUS TESTS 8
DIAGNOSTICS STATE 4 - L1FEPULSE TESTS (LC9500HR Integrated PCB Only) 9
DIAGNOSTICS STATE 5 - LOOPBACK TESTS 10
DIAGNOSTICS STATE 5 - CVA ENABLEIDISABLE (LC9500HR Integrated PCB Only)
11
DIAGNOSTICS STATE 6 - MAXIMUM PROGRAM DURATION 12
DIAGNOSTICS STATE 7 - TELEMETRY ENABLEIDISABLE 13
DIAGNOSTICS STATE 8 - ENGLlSHlMETRIC UNITS 14
DIAGNOSTICS STATE 9 - MODEL SELECTION 15
DIAGNOSTICS STATE 10 -WATTS PROGRAM ENABLEIDISABLE 16
DIAGNOSTICS STATE
11 -METS PROGRAM ENABLEIDISABLE 17
DIAGNOSTICS STATE 12 -POWER SUPPLY CONFIGURATION 18
DIAGNOSTICS STATE 13 -TOTAL HOURS AND STATiSTiCS 19
DIAGNOSTICS STATE 14 -NUMERIC KEYS CONFIGURATION 20
DIAGNOSTICS STATE 15 -PHOTO SHOOT
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Lifecycle 9100 and 9500HR Series Exercise Bikes
TABLE OF CONTENTS •
SECTION II DIAGNOSTIC MODES -CONTINUED
DIAGNOSTICS STATE 15 -PROGRAMS ENABLEIDISABLE
(LC9500HR Integrated PCB Only) 22
DIAGNOSTICS STATE 16 -LANGUAGE SELECTION
(LC9500HR Integrated PCB Only) 23
DIAGNOSTICS STATE 17 -EEPROM TEST (LC9500HR Integrated PCB Only) 24
DIAGNOSTICS STATE 18 -PHOTO SHOOT (LC9500HR Integrated PCB Only) 25
NOTES 26
SECTION III How To ...REMOVE AND REPLACE•..
THE ALTERNATOR 2
ALTERNATOR BELT 3
DRIVE BELT 4
CRANK ARM AND BEARINGS 5
SEAT ASSEMBLY 7
MAIN WIRE HARNESS 8
BATTERY -MODEL LC9500 10
BATTERY -MODEL LC9100 11
DISPLAY CONSOLE 12
ALTERNATOR CONTROL BOARD 13
FOOT STRAP 14
FRONT WHEELS 15
HANDLEBAR ASSEMBLy 16
DIGITAL HEART RATE SENSORS 18 •
HEART RATE PC BOARD 20
HOUSING 21
PEDALS 22
SEAT PLUNGER 23
STABILIZER BAR 24
TELEMETRY RECEIVER 25
NOTES 26
SECTION IV
ELECTRONICS OVERVIEW
DISPLAY CONSOLE BOARD -Model LC91 00 2
DISPLAY CONSOLE BOARD -Model LC9500 Integrated PCB 3
DISPLAY CONSOLE BOARD -Model LC9500 DSP Heart Rate PCB 5
ALTERNATOR CONTROL BOARD -Model LC9100 7
ALTERNATOR CONTROL BOARD -Model LC9500 8
ALTERNATOR 9
WIRING BLOCK DIAGRAM -Model 9100 10
WIRING BLOCK DIAGRAM -Model 9500 w/lntegrated PCB 11
WIRING BLOCK DIAGRAM -Model 9500 w/DSP Heart Rate Board 12
NOTES 13
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Lifecycle 9100 and 9500HR Series Exercise Bikes
TABLE OF CONTENTS
SECTION V
MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION 2
LC9500HR GK46-00001-XXXX (SN190000-199207) 3
LC9500HR GK46-00005-XXXX (SN199208-202685) 5
LC9500HR GK46-00006-XXXX (SN202686-212728) 7
LC9500HR GK46-00007-XXXX (212727-UP) 9
LC9500HR LC95-0100-1 0 11
LC91 00 GK49-00007-XXXX 13
NOTE 15
SECTION VI
PREVENTATIVE MAINTAINENCE TIPS 2
UNPACKING INSTRUCTIONS FOR MODELS LC91 00 AND 9500HR 3
INSTALLATION INSTRUCTIONS MODEL LC91 00 4
INSTALLATION INSTRUCTIONS MODEL LC9500 10
COMMUNICATING BY FAX 15
FAX FORM 16
NOTES 17

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Lifecycle 9100 and 9500HR Series Exercise Bikes
SECTION I
TROUBLESHOOTING
GUIDES
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Lifecycle 9100 and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Malfunction Probable Cause
Corrective Action
Display Console LEOs not
Pedaling to slowly Pedal faster than 45 RPM then press the
illuminating
START button.
Kevoad not respondinQ MassaQe kevoad with finQertips.
Insufficient battery voltage Check battery voltage. The LC9500 has a
6VDC battery (non alkiline) which
should test
out between 5.8 to 6.3 VDC. The LC91 00 has a
9VDC alkaline battery and it should test out
between (8.8 -9.2VDC).
Loose wire connections Disconnect then reconnect connections.
Worn or damaged wire Inspect wire hamesses. Replace worn or
hamesses damaged harness.
Malfunctioning display console Test with substitute display console. Replace
malfunctioning display console.
Malfunctioning alternator Test with substitute ACB. Replace
control board (ACB) malfunctioninQ ACB.
Malfunctioning alternator Test Alternator output or test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
Display console initializes Loose wire connections Disconnect then secure connections.
then fails
Worn or darnaged wire Inspect wire harnesses. Replace worn or
harnesses damaged harness.
Malfunctioning display console Test with substitute display console. Replace
malfunctioning display console.
Malfunctioning alternator Test with substitute altemator control board.
control board Replace malfunctioning board.
Malfunctioning alternator Test alternator output or test with substitute
alternator. Replace malfunctioning altemator.
Refer to Alternator VoltaQe Test.
No prompt upon release of
Malfunctioning display console Test with substitute display console. Replace
START key.
Entry of
malfunctioning display console.
additional information not
allowed.
Malfunctioning alternator Test with substitute ACB. Replace defective
control board alternator control board.
Malfunctioning alternator Test alternator output or test with substitute
alternator. Replace malfunctioning alternator.
Refer to Alternator
VoltaQe Test.
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•Lifecycle 9100
and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Display Console LEOs are
not constant
Pedaling to slowly
Insufficient battery voltage
Loose wire connections
Check battery voltage. The LC9500 has a
6VDC battery (non alkiline) which
should test
out between 5.8 to 6.3 VDC. The LC91 00 has a
9VDC alkaline battery and it should test out
between 8.8 -9.2VDC .
Disconnect then reconnect connections.
Worn or damaged wire
hamesses Inspect wire harnesses. Replace worn or
dama
ed harnesses.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctionin Dis la Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board.
Re lace malfunctionin board.
Test Alternator output or test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Volta eTest.
Inspect wire harnesses. Replace worn or
dama ed hamesses.
Disconnect then reconnect the connections.
Wom or damaged harnesses
Malfunctioning Altemator
Loose wire connections
Display Console LEOs do
not extinguish in timely
manner at the end of a
workout, when the CLEAR
key is pressed, or when the ~~~~~-..,....,....-----+-""'~-.,....,.....--,-,.----,,..,.....--.....,,..----,.~------l
pedaling stops. Malfunctioning A1temator Test with substitute Alternator Control Board.
Control Board
Re lace defective board.
•
Malfunctioning Display Console Inspect for damage or depression at START
key. Test with substitute Display Console.
Re lace malfunctionin Dis la Console.
Prompt persistently flashes Pedaling too slowly
and entry of additional
information is not allowed. Attempting to enter improper
duration of time
Pedal faster than 45 RPM.
Refer to Operation Manual for time duration
re uirements.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctionin Dis la Console.
Malfunctioning Altemator
Control Board ACB Test with substitute Alternator Control Board.
Re lace Malfunctionin board.
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Lifecycle 9100 and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Malfunction Probable Cause
Corrective Action
Display Console keys Attempting to enter program Refer to Operation Manual for program
(except START key) do not
not available. availabilitv.
function and Exercise Bike
does not respond. Keypad is cold Massaoe keypad with finoertips.
Display Console connection Test with substitute Display Console. Replace
loose malfunctionino Display Console.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctionino Display Console.
Upon start of program, Pedaling too slowly Pedal faster than 45 RPM.
excessive resistance load
is immediate; no normal, Insufficient battery voltage Check battery voltage. The LC9500 has a
incremental increase from
6VDC battery (non alkiline) which should test
"no load."
out between 5.8 to 6.3 VDC. The LC91 00 has a
9VDC alkaline battery and it should test out
between (8.8 -9.2VDC).
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged wire Inspect wire harnesses. Replace worn or
harnesses damaoed harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator Test with substitute Altemator Control Board.
Control Board Replace malfunctionino board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Altemator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
During program, excessive Pedalino too slowly Pedal faster than 45 RPM.
resistance loading occurs.
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged wire Inspect wire harnesses. Replace worn or
harnesses damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator Test with substitute ACB. Replace
Control Board (ACB) malfunctionino ACB.
Malfunctioning Alternator Test Alternator output or, test with substitute
Altemator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
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Lifecycle 9100 and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
III"'. e1
I~"eh~ e ~R:
-
elII tI.:.I".
ell
.
During MANUAL program, Pedalina too slowly Pedal faster than 45 RPM.
~
resistance variation occurs.
Loose wire connections Disconnect then, reconnect connections.
";
t;
Worn or damaged harnesses Inspect wire harnesses. Replace worn or
~
damaaed harness. •
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Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctionina Display Console.
Malfunctioning Alternator Test with substitute Alternator Control Board.
Control Board Replace defective board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltaae Test.
During RANDOM or HILL
Loose wire connections Disconnect then, reconnect connections.
programs, resistance is
constant without variation
Worn or damaged harnesses Inspect wire harnesses. Replace worn or
for interval training nor hill
damaaed harness.
incline/decline. Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctionina Disolav Console.
Malfunctioning Alternator Test with substitute Alternator Control Board.
Control Board Reolace defective board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltaae Test.
Pedaling is difficult, feels Malfunctioning Pulley Clutch Inspect Clutch for free backward and forward
restricted or, is not
Assembly rotation. Replace malfunctioning Pulley Clutch
possible when Exercise or Freewheel.
Bike has not been started
(START key
not pressed). Alternator Belt excessively tight Inspect belt deflection. Adjust as necessary.
Altemator Belt Deflection: 1/4 inch (6mm)
Alternator Belt Alignment is not Realign alternator belt to center.
centered
Left side Crank Nut to tiaht Loosen nut 1/16 (one sixteenth) of atum.
Crank bearings worn or Replace Crank Bearings.
corroded
Seat incorrectly adiusted Adiust Seat. Refer to Operation Manual.
5

Lifecycle 9100 and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Malfunction Probable Cause
Corrective Action
During exercise program, Pedaling too slowly Pedal faster than
45 RPM.
pedaling is insufficiently
easy, not providing Program level doesn't Select higher level.
adequate resistance. challenge
user abilitv
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged harnesses Inspect wire harnesses. Replace
wom or
damaged harness.
Malfunctioning Display Console
Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Test with substitute Altemator Control Board.
Control Board Replace defective board.
Malfunctioning Alternator
Test Alternator output or, test with substitute
Altemator. Replace malfunctioning Altemator.
Refer to Alternator Voltage Test.
Alternator Belt excessively Inspect belt deflection. Adjust as necessary.
loose Alternator Belt Deflection: 1/4 inch (6mm)
Drive Belt excessively loose Inspect Belt. Replace Belt.
Battery over-heating during Battery Wires incorrectly Inspectconnections: red wire to positive (+)
exercise program. connected lead; black wire to negative (-) lead.
Worn Battery Wires Inspect Wires. Replace
Wires or harness.
Battery leads grounding upon Inspect leads. Replace battery.
frame
Malfunctioning Display Console
Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Test with substitute Alternator Control Board.
Control Board Replace defective board.
Exercise Bike not stable Stabilizer Foot Pads not Adjust Foot Pads.
upon floor. adjusted correctly
Floor surface
not level Position Exercise Bike upon level surface.
Stabilizer Bar
not attached Tighten attaching hardware.
firmly to frame
Wheel(s) darnaged Replace darnaged wheel(s).
Frame damaged Contact Customer Support Services.
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•Lifecycle 9100
and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
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During exercise program,
loud noise issuing from
Exercise Bike.
Non-carpeted. hard surface
floor
Improper riding style
Crank Bearings not adjusted
ro ert or. worn
Alternator Belt excessively
loose
Alternator Belt worn
Malfunctioning Alternator
Drive Belt excessivel loose
Free-wheel Pulley Assembly
Malfunctioning Alternator
Change style. Do not lean excessively to either
side.
Inspect Bearings. Adjust or replace as
necessa .
Inspect belt deflection. Adjust as necessary.
Alternator Belt Deflection: 1/4 inch 6mm
Re lace Belt.
Operate Exercise Bike as
in normal use with
light and heavy load levels. Listen for excessive
noise from Alternator. Replace Alternator as
necessa .
Ins
Inspect Alternator voltage.
1. Attach DC voltmeter to Alternator. Voltmeter
positive (+) probe to Alternator red lead.
Voltmeter negative (-) lead to Alternator black
lead.
2. Maintain pedal speed greater than 45 RPM.
3. Press START key.
Alternator Voltage Specification: 9 - 11 VDC
when dal sed reater than 45 RPM
7

Lifecycle 9100 and 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Malfunction
Probable Cause
Corrective Action
No heart rate or, display
No heart rate reading Executive Diagnostic Mode to verify
reads (No HR). 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. See wiring diagram for pin
location.
Malfunctioning Replace Handlebar/Lifepulse Assembly.
Handlebar/Lifepulse Grip
Assembly (include. wom or
damaged heart rate lead)
Life Pulse handlebar Verify that the handlebar is functioning. See
diagrams.
Using an ohmmeter, verify continuity between
Lifepulse sensor and cable connection. See
wiring diaoram for pin location.
Handlebar/Lifepulse Grip Dry wipe sensors.
Assembly
Loose or malfunctioning heart Secure connection. Replace malfunctioning
rate lead connection at Display Handlebar/Lifepulse Grip Assembly
Console
Heart-rate (DSP) Board Verify that the heart-rate (DSP) board is
communicating. See Diagnostic/
Replace faulty heart-rate (DSP) board.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctionino Display Console.
Handlebar grips loosening
Excessive wear or damage to Replace the handlebar assembly.
grip
Lifepulse sensor molding
Cleaning solution that contains Replace the Lifepulse Sensor Kit.
loose
an acid or ammonia base.
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Lifecycle 9100 and 9500HR Series Exercise Bikes
NOTES:
9

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