Life Fitness 9500HR User manual

Lifecycle



9500HR Belt Drive Series Exercise Bikes
Customer Support Services
SERVICE MANUAL
TM

Lifecycle 9500HR Series Exercise Bikes
INTRODUCTION
HOW TO USE SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to LifecycleModel 9500HR (via Lifepulse digital and Polar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
TROUBLESHOOTING GUIDES
Section II
DIAGNOSTIC MODE
Section III
"How To..." SERVICE AND REPAIR GUIDES
Section IV
PARTS IDENTIFICATION
WIRING BLOCK DIAGRAMS
Section V
MISCELLANEOUS 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.
A reproducible 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, 7 days/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.

Lifecycle 9500HR Series Exercise Bikes
THEORY OF OPERATION
The Lifecycles bikes are stationary exercise bicycles that provide a scientific 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 a range 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 0 resistance - almost 25% easier than the level 1 found 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 a program 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 a day.
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]...........Toll-free: 800.351.3737
FAX: [phone].....................Toll-free: 800.216.8893

Lifecycle 9500HR Series Exercise Bikes
TABLE OF CONTENTS
INTRODUCTION
How to use this Service Manual
Theory of Operation
SECTION I
TROUBLESHOOTING GUIDES PAGE
NO POWER ..........................................................................................................................2
DISPLAY CONSOLE INITIALIZES THEN FAILS ................................................................3
ERRATIC DISPLAY CONSOLE L.E.D.S..............................................................................4
DISPLAY CONSOLE L.E.D.S REMAIN ILLUMINATED......................................................5
PROMPT PERSISTS AND INFORMATION ENTRY NOT ALLOWED................................6
PROMPT EXTINGUISHES WHEN START KEY IS RELEASED
AND INFORMATION ENTRY NOT ALLOWED..................................................................7
DISPLAY CONSOLE KEYS DO NOT FUNCTION ..............................................................8
IMMEDIATE, EXCESSIVE RESISTANCE LOAD AT START OF PROGRAM ...................9
EXCESSIVE RESISTANCE LOAD DURING PROGRAM....................................................10
RESISTANCE VARIES DURING MANUAL PROGRAM......................................................11
RESISTANCE CONSTANT DURING RANDOM OR HILL PROGRAMS ............................12
DIFFICULT OR NO PEDALING MOVEMENT .....................................................................13
PEDALING TOO EASY ........................................................................................................14
BATTERY OVER-HEATING.................................................................................................15
NOT STABLE .......................................................................................................................16
EMITTING LOAD NOISE......................................................................................................17
ALTERNATOR VOLTAGE TEST.........................................................................................18
NO HEART RATE OR DISPLAY READS NO HEART RATE..............................................19
HANDLEBAR/LIFEPULSE GRIPS LOOSE .........................................................................20
SECTION II
DIAGNOSTIC MODES
DIAGNOSTICS STATE – HOW TO ENTER……………………………………………………..2
DIAGNOSTICS STATE – OVERVIEW……………………………………………………………3
DIAGNOSTICS STATE 1 - ALL LEDS and KEYPAD TEST ................................................4
ALL LED TEST
KEYPAD TEST
SPEAKER TEST
DIAGNOSTICS STATE 2 - INDIVIDUAL LED TEST ............................................................4
INDIVIDUAL LED TEST
DIAGNOSTICS STATE 3 - VERSION #: RPM, HR, and LOAD TESTS...............................5
PROGRAM VERSION NUMBER
PEDAL RPM
HEART RATE
LOAD DUTY CYCLE CONTROL
DIAGNOSTICS STATE 4 - LIFEPULSE and NETWORK STATUS TESTS ........................5
LIFEPULSE HC05 and DSP PROGRAM VERSION.REVISION #s
LIFE LINK CONNECTION STATUS
DIAGNOSTICS STATE 5 - LOOPBACK TESTS ..................................................................5
LOOPBACK TEST FOR CVA COMMUNICATIONS
DIAGNOSTICS STATE 6 - MAXIMUM PROGRAM DURATION..........................................6
MAXIMUM PROGRAM TIME
DIAGNOSTICS STATE 7 - TELEMETRY ENABLE/DISABLE.............................................6
TELEMETRY ENABLE/DISABLE
DIAGNOSTICS STATE 8 - ENGLISH/METRIC UNITS.........................................................6
ENGLISH UNITS/METRIC UNITS CONFIGURATION
DIAGNOSTICS STATE 9 - UPRIGHT/RECUMBENT SELECTION .....................................7
LC9500 or LC9500R CONFIGURATION

Lifecycle 9500HR Series Exercise Bikes
TABLE OF CONTENTS (continued)
DIAGNOSTICS STATE 10 - WATTS.....................................................................................7
WATTS ENABLED / DISABLED
DIAGNOSTICS STATE 11 - METS .......................................................................................7
METS ENABLED / DISABLED
STATISTICS (OPTIONAL)
DIAGNOSTICS STATE 12 – POWER SUPPLY CONFIGURATION....................................8
6-VOLT BATTERY / EXTERNAL POWER SUPPLY / 9-VOLT BATTERY / CVA
DIAGNOSTICS STATE 13 – TOTAL HOURS AND STATISTICS........................................8
TOTAL HOURS AND STATISTICS ARE SHOWN
DIAGNOSTICS STATE 14 - NUMERIC KEYS CONFIGURATION…………………………..8
NUMERIC KEYS ENABLED / DISABLED
DIAGNOSTICS STATE 15 – PHOTO SHOOT…………………………………………………..8
SOLELY USED FOR A PHOTO SHOOT
SECTION III
How To...REMOVE AND REPLACE…
THE ALTERNATOR..........................................................................................................2
ALTERNATOR BELT .......................................................................................................3
DRIVE BELT......................................................................................................................4
CRANK ARM AND BEARINGS.........................................................................................5,6
SEAT ASSEMBLY.............................................................................................................7
MAIN WIRE HARNESS.....................................................................................................8,9
BATTERY ..........................................................................................................................10
DISPLAY CONSOLE.........................................................................................................11
ALTERNATOR CONTROL BOARD .................................................................................12
FOOT STRAP....................................................................................................................13
FRONT WHEELS ..............................................................................................................14
HANDLEBAR ASSEMBLY................................................................................................15,16
DIGITAL HEART RATE SENSORS..................................................................................17,18
HEART RATE PC BOARD................................................................................................19
HOUSING ..........................................................................................................................20
PEDALS.............................................................................................................................21
SEAT PLUNGER...............................................................................................................22
STABILIZER BAR .............................................................................................................23
TELEMETRY RECEIVER..................................................................................................24
SECTION IV
WIRING BLOCK DIAGRAMS............................................................................................................2
PARTS LISTS....................................................................................................................................3-10
SECTION V
MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION.....................................................2
PREVENTATIVE MAINTAINENCE TIPS ..........................................................................................3
COMMUNICATING BY FAX..............................................................................................................4
FAX FORM.........................................................................................................................................5
MISCELLANEOUS NOTES...............................................................................................................6

TM
©1999 Brunswick Corporation. All rights reserved. Life Fitness and Lifecycle are registered trademarks of Brunswick Corporation.
Lifepulse, Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation. Any use of these trademarks, without the
express written consent of Brunswick Corporation, is forbidden.
M051-00K46-A004
1/99

1
Lifecycle 9500HR Series Exercise Bikes
SECTION I
TROUBLESHOOTING
GUIDES

2
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: No Power
Symptom Probable Cause Corrective Action
Display Console LEDs do
not illuminate Pedaling too slowly Pedal faster than 45 RPM then press the
START button.
Keypad not responding Massage keypad with fingertips.
Insufficient battery voltage Test the battery voltage. It should be:
5.8 to 6.3 VDC. If necessary, replace the
battery with a fully charged 6V battery.
Loose wire connections Disconnect then reconnect connections.
Worn or damaged wire
harnesses. Inspect wire harnesses. Replace worn or damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board (ACB) Test with substitute ACB. Replace malfunctioning ACB.
Malfunctioning Alternator Test Alternator output or test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact:
Life Fitness Customer Support Services
847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

3
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Display Console Initializes Then Fails
Symptom Probable Cause Corrective Action
Display Console initializes
then fails Loose wire connections Disconnect then secure connections.
Worn or damaged wire
harnesses Inspect wire harnesses. Replace worn or damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace malfunctioning board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

4
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Erratic Display Console LEDs
Symptom Probable Cause Corrective Action
Display Console LEDs are
not constant Pedaling too slowly Pedal faster than 45 RPM.
Insufficient battery voltage Test the battery voltage. It should be:
5.8 to 6.3 VDC. If necessary, replace the
battery with a fully charged 6V battery.
Loose wire connections Disconnect then reconnect connections.
Worn or damaged wire
harnesses Inspect wire harnesses. Replace worn or damaged harnesses.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace malfunctioning board.
Malfunctioning Alternator Test Alternator output or test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

5
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Display Console LEDs Remain Illuminated
Symptom Probable Cause Corrective Action
Display Console LEDs do
not extinguish in timely
manner at the end of a
workout , when the CLEAR
key is pressed, or when the
pedaling stops.
Loose wire connections Disconnect then reconnect the connections.
Worn or damaged harnesses Inspect wire harnesses. Replace worn or
damaged harnesses.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace defective board.
Malfunctioning Display Console Inspect for damage or depression at START
key. Test with substitute Display Console.
Replace malfunctioning Display Console.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

6
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Prompt Persists and Information Entry Not Allowed
Symptom Probable Cause Corrective Action
Prompt persistently flashes
and entry of additional
information is not allowed.
Pedaling too slowly Pedal faster than 45 RPM.
Attempting to enter improper
duration of time Refer to Operation Manual for time duration requirements.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board (ACB) Test with substitute Alternator Control Board. Replace Malfunctioning board.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

7
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Prompt Extinguishes When Start Key Is Released and Information Entry Not
Allowed
Symptom Probable Cause Corrective Action
Prompt extinguishes when
START key is released and
entry of additional
information is not allowed.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute ACB. Replace defective Alternator Control Board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

8
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Display Console Keys Do Not Function
Symptom Probable Cause Corrective Action
Display Console keys
(except START key) do not
function and Exercise Bike
does not respond.
Attempting to enter program
not available. Refer to Operation Manual for program availability.
Keypad is cold Massage keypad with fingertips.
Display Console connection
loose Test with substitute Display Console. Replace malfunctioning Display Console.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

9
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Immediate, Excessive Resistance Load at Start of Program
Symptom Probable Cause Corrective Action
Upon start of program,
excessive resistance load
is immediate; no normal,
incremental increase from
“no load.”
Pedaling too slowly Pedal faster than 45 RPM.
Insufficient battery voltage Test battery voltage or replace with fully
charged 6V battery.
Battery Voltage Specification: 5.8 - 6.3 VDC
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged wire
harnesses Inspect wire harnesses. Replace worn or damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace malfunctioning board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

10
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Excessive Resistance Load During Program
Symptom Probable Cause Corrective Action
During program, excessive
resistance loading occurs. Pedaling too slowly Pedal faster than 45 RPM.
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged wire
harnesses Inspect wire harnesses. Replace worn or damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board (ACB) Test with substitute ACB. Replace malfunctioning ACB.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

11
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Resistance Varies During Manual Program
NOTE: In RANDOM and HILL programs, resistance variation may be normal. Test for resistance variation in
MANUAL program.
Symptom Probable Cause Corrective Action
During MANUAL program,
resistance variation occurs. Pedaling too slowly Pedal faster than 45 RPM.
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged harnesses Inspect wire harnesses. Replace worn or
damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace defective board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

12
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Resistance Constant During Random or Hill Programs
NOTE: In RANDOM and HILL programs, resistance variation may be normal. Test for resistance variation in
MANUAL program.
Symptom Probable Cause Corrective Action
During RANDOM or HILL
programs, resistance is
constant without variation
for interval training nor hill
incline/decline.
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged harnesses Inspect wire harnesses. Replace worn or
damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace defective board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

13
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Difficult or NO Pedaling Movement
Symptom Probable Cause Corrective Action
Pedaling is difficult, feels
restricted or, is not
possible when Exercise
Bike has not been started
(START key not pressed).
Malfunctioning Pulley Clutch
Assembly Inspect Clutch for free backward and forward rotation. Replace malfunctioning Pulley Clutch
or Freewheel.
Alternator Belt excessively tight Inspect belt deflection. Adjust as necessary.
Alternator Belt Deflection: 1/4 inch (6mm)
Alternator Belt Alignment is not
centered Realign alternator belt to center.
Left side Crank Nut excessively
tight Loosen nut 1/16 (one sixteenth) of a turn.
Crank Bearings worn or
corroded Replace Crank Bearings.
Seat incorrectly adjusted Adjust Seat. Refer to Operation Manual.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

14
Lifecycle 9500HR Series Exercise Bikes
TROUBLESHOOTING GUIDE
Symptom: Pedaling Too Easy
NOTE: Exercise Bike utilizes “constant work” principle - pedal faster/less resistance, pedal slower/greater
resistance.
Symptom Probable Cause Corrective Action
During exercise program,
pedaling is insufficiently
easy, not providing
adequate resistance.
Pedaling too slowly Pedal faster than 45 RPM.
Program level doesn’t
challenge user ability Select higher level.
Loose wire connections Disconnect then, reconnect connections.
Worn or damaged harnesses Inspect wire harnesses. Replace worn or
damaged harness.
Malfunctioning Display Console Test with substitute Display Console. Replace
malfunctioning Display Console.
Malfunctioning Alternator
Control Board Test with substitute Alternator Control Board. Replace defective board.
Malfunctioning Alternator Test Alternator output or, test with substitute
Alternator. Replace malfunctioning Alternator.
Refer to Alternator Voltage Test.
Alternator Belt excessively
loose Inspect belt deflection. Adjust as necessary.
Alternator Belt Deflection: 1/4 inch (6mm)
Drive Belt excessively loose Inspect Belt. Replace Belt.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893