Life Fitness LS 9100 User manual

Life Fitness 9100/9500HR Belt Drive Series Stairclimbers
CUSTOMER SUPPORT SERVICES
SERVICE MANUAL
LS 9100
LS 9500HR

Life Fitness 9100/9500HR Belt Drive Stairclimbers
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Model LS 9100 (heart rate function via telemetry) and Model LS 9500HR (heart rate
function via Lifepulsedigital sensors and telemetry) belt drive stairclimbers.Information is appropriate to both models unless
otherwise noted.
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. The manual is
separated into five sections. INTRODUCTION
TABLE OF CONTENTS
THEORY OF OPERATION
Section I
qTROUBLESHOOTING GUIDES
Section II
qDIAGNOSTIC MODE
Section III
q"How To..." SERVICE AND REPAIR GUIDES
Section IV
qPARTS IDENTIFICATION
qWIRING BLOCK DIAGRAMS
Section V
qMISCELLANEOUS 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.
Reproducible telefacsimile order claim form is provided in COMMUNICATING BY TELEFACSIMILE for convenient ordering of
service parts.
To order, contact Life Fitness Customer Support Services.
Via telefacsimile - 24 hrs. /day, 7 days/week.
Via telephone - Monday through Friday from 8:00 AM to 6:00 PM ( C.S.T.).
Via post - At address cited.
To expedite 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.
If you have questions or comments please telephone, ‘fax or, write us. We are:
CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue; Franklin Park, IL 60131; U.S.A.
Telephone: [phone] or, Toll Free 800.351.3737 Telefacsimile: 847.288.3702 or, Toll Free 800.216.8893

Life Fitness 9100/9500HR Belt Drive Stairclimbers
THEORY OF OPERATION
The electronics system of the Life Fitness LS 9500HR and LS 9100 belt drive stairclimbers is made up of three
distinct modules; the Power Entry Module, the Display Console, and the Power Control Board.
120 volts AC enters the Power Entry Module. It passes through a transformer and is converted to 14 volts AC. The
14 volts AC is applied to the Power Control Board at connector J4, pins 1 and 2. The voltage passes through a
bridge rectifier, BR1 and is converted to an unregulated positive DC voltage. This unregulated voltage will vary from
11 volts DC to 18 volts DC depending on the wall supply and load. This voltage can be measured by placing the
positive probe of your DVM on Positive Test Point at BR1 and the negative probe on the negative Test Point at
BR1.
The other voltage developed on the Power Control Board is a regulated positive 8 volts DC. The regulated 8 volts
DC is developed by transistor (Q2) . This voltage can be measured by placing the positive probe of your DVM on
the collector (case) of Q2 and the negative probe on the anode of D1.
This 8 volts DC is supplied to the Console at connector J1, pin 4 and is used to power the LED’s. The 8 volts DC is
also used as a supply voltage for the positive 5 volt DC regulator (U1) on the Console board, which is VCC for the
Microprocessor. The Keypad entry (user’s input), Life Pulse (9500HR only), and Telemetry are all processed by the
Microprocessor.
The Console, by pulse width modulating the field control line, sends a signal to the Power Control Board at J1, pin
1. The Power Control Board switches the field current to the Alternator, through Q1. This field current along with
the energy supplied by the user is sent to the Load Resistors. This places resistance on the rotation, thus providing
the load sensation felt by the user.
The Alternator also provides the source for the RPM sensor circuit. The AC tap output on the Alternator enters the
Power Control Board at J2, pin 3. This AC voltage is wave conditioned and outputted at connector J1, pin 2 to the
Console connector P2, pin 6. Where it is processed and displayed by the Console.
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See Wiring Diagram for more detailed information

PLACE HOLDER
FOR BLANK
PAGE BACK OF
INTRODUCTION
PAGE

Life Fitness 9100/9500HR Belt Drive Stairclimbers
TABLE OF CONTENTS
INTRODUCTION
How to use this Service Manual
Theory of Operation
SECTION I PAGE
TROUBLESHOOTING GUIDES…………………………………………………………………………………. 1
SYMPTOM
Handlebar/Lifepulse Grips Loose (9500HR Only)...................................…………………….. 2
Grinding Noise, Slipping, Both Pedals Are On The Floor........................................………… 3
No Power......................................................................................................………………… 4
Display Console Keys Do Not Function...............................................................…………… 5
Display Console Initializes Then Fails..................................................................………….. 6
Erratic Display Console LED’s...........................................................................…………….. 7
Immediate, Excessive Resistance Load At Start Of Program..................................………... 8
Immediate, Excessive Resistance Load During Program.........................................……….. 9
Inaccurate Count Of Steps - Goal Or Actual........................................................…………… 10
Excessive Resistance Varies During Program.......................................................…………. 11
Resistance Varies During Program.....................................................................……………. 12
Display Has No RPM........................................................................................……………… 13
No Heart Rate or Display Readout......................................................................…………… 14
Erratic Heart Rate Display.................................................................................…………….. 15
SECTION II PAGE
DIAGNOSTIC MODE 1
How To... EXECUTE (Large Display) 2
To Enter Diagnostic……………………………………………………………………………….. 3
Keypad Test……………………………………………………………………………………….. 3
Led Test……………………………………………………………………………………………. 4
Alternator test……………………………………………………………………………………… 5
Options Mode………………………………………………………………………………………. 6
Statistics Mode…………………………………………………………………………………….. 7
EEROM Statistics…………………………………………………………………………………. 8
Enable Lifepulse…………………………………………………………………………………… 9
How To... EXECUTE (Small Display) 10
To Enter Diagnostic………………………………………………………………………………… 11
Keypad Test………………………………………………………………………………………… 11
Led Test…………………………………………………………………………………………… 12
Program Version………………………………………………………………………………….. 12
Network Status…………………………………………………………………………………….. 12
Program Duration………………………………………………………………………………….. 13
Telemetry……………………………………………………………………………………………. 13
English or Metric Units…………………………………………………………………………….. 13
Watts (On/Off)……………………………………………………………………………………… 13
Mets (On/Off)……………………………………………………………………………………….. 13
Total Hours…………………………………………………………………………………………. 14
Model Selection……………………………………………………………………………………..
Photo-Shoot…………………………………………………………………………………………. 14 14

Life Fitness 9100/9500HR Belt Drive Stairclimbers
TABLE OF CONTENTS (CONTINUED)
SECTION III PAGE
HOW TO…SERVICE AND REPAIR GUIDES…………………………………………………………………. 1
Boot/Collar .....................................................................................................………………. 2
Alternator Belt...............................................................................................………………… 3
Alternator .....................................................................................................………………… 5
Drive Belt............................................................................................................……………. 6
Monocolumn..................................................................................................……………….. 7
Cross-Over Pulley.......................................................................................…………………. 9
Display Console..............................................................................................………………. 10
Foot Pad........................................................................................................……………….. 12
Housing.........................................................................................................………………… 13
Molded Handle Assembly.................................................................................……………… 14
Power Board..................................................................................................……………….. 15
Power Module................................................................................................……………….. 16
Main Pulley............................................................................................................…………. 18
Spring - Lower................................................................................................……………….. 20
Spring - Upper................................................................................................……………….. 21
Handlebar/Lifepulse Sensor Assembly................................................................…………… 22
Telemetry Receiver………………………………………………………………………………… 23
Digital Heart Rate Sensors.(9500HR Only).................................................…………………. 24
Digital Heart Rate PC Board………………………………………………………………………. 26
SECTION IV PAGE
PARTS IDENTIFICATION AND WIRING BLOCK DIAGRAMS
LS9100 GK24-00021-0100 ( SN# 216142 – UP)………………………………………. 2
LS9500HR GK24-00022-0100 ( SN# 146749 – 148124)…………………………………. 5
LS9500HR GK24-00023-0100 ( SN# 148125 – UP)………………………………………. 8
LS9100 GK24-00025-0100 ( SN# 218304 – UP)………………………………………. 11
LS9500HR GK24-00027-0100 ( SN# 148125 – UP)………………………………………. 14
Wiring Block Diagram (9500HR)………………………………………………………………….. 17
Wiring Block Diagram (9500HR)………………………………………………………………….. 18
Wiring Block Diagram (9100)……………………………………………………………………… 19
SECTION V PAGE
MISCELLANEOUS INFORMATION 1
Model and Serial Numbers Locations .............................................................................…2
Preventive Maintenance …………………………………………………………………………. 3
Communicating By Telefacsmile (Instructions) .....................................…………………….. 4
Warranty/Sales Order Claim Form………………………………………………………………. 5

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.
M051-00K24-A183
1/99

1
Life Fitness 9100/9500HR Belt Drive Stairclimbers
SECTION I
TROUBLESHOOTING
GUIDES

2
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDE
Symptom: HANDLEBAR/LIFEPULSE GRIPS LOOSE
Symptom Probable Cause Corrective Action
Handlebar grips loosening. Excessive wear or damage to
grip. Replace Lifepulse Handle Assembly.
Lifepulse sensor molding
loose. Cleaning solution used
containing acid or ammonia. Replace Lifepulse sensor kit.
For Assistance Contact
Life Fitness Customer Support Services
Teleph.: 847.451.0036 or 800.351.3737
Telefacs.: 847.288.3702 or 800.216.8893

3
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: GRINDING NOISE, SLIPPING, BOTH PEDALS ARE ON THE FLOOR
Symptom Probable Cause Corrective Action
Grinding noise during
program. Clutches Inspect the clutch bearings for wear.
Replace the worn clutch.
Pulleys Inspect for wear.
Replace worn pulley.
Alternator For noise or vibration in the bearing shaft,
relieve tension on the alternator belt. Spin
flywheel and inspect.
Replace Alternator.
Slipping Cross-over belt Inspect belt for cracked or missing teeth.
Replace damaged belt.
Clutches Inspect for slipping / Replace if necessary.
Alternator Belt Inspect belt for proper tension and wear.
Replace if necessary.
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
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: NO POWER
Symptom Probable Cause Corrective Action
Display Console LED’s do
not illuminate Power supply not 115VAC Make certain power supply is 115VAC.
AC Line cord not connected
securely in wall outlet or
damaged
Verify line cord is not damaged and that it is
Properly plugged in.
Unit power switch (I/O) not in
on position Place power switch in ON (I) position.
Loose wire connections, or
wire connectors not seated
properly
Disconnect then reconnect all harness
connections at Display Console and Power
Control Board.
See How To... Remove Shroud Assembly.
Damage cable Using an ohmmeter, verify continuity of wire
harness. Replace worn or damaged wire
harness.
Faulty Display Console Using a voltmeter, verify power at the cable and
Display Console connection. See wiring
diagram for pin location…Replace Display if
proper voltage is present.
10 amp circuit breaker tripped Reset 10-amp circuit breaker.
Damaged 10 amp circuit
breaker Using an ohmmeter, verify the circuit breaker is functioning. Replace faulty part.
2 amp circuit breaker tripped Reset 2-amp circuit breaker.
Damaged 2 amp circuit
breaker Using an ohmmeter, verify the circuit breaker is functioning. Replace faulty part.
Blown 5 amp slow blown fuse
on the Power Control Board Using a voltmeter, verify power at test points. See How To... Replace Power Control Board.
Replace faulty PCB.
Faulty Power Module
Transformer Assembly. Using a voltmeter, verify 14.5 VAC across, J4 connector on the Power Control Board. See
wiring diagram. Replace faulty Power Module
and Transformer assembly.

5
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: DISPLAY CONSOLE KEYS DO NOT FUNCTION
Symptom Probable Cause Corrective Action
Display Console keys do
not function Attempting to enter program
not available. Refer to Operation Manual for program availability.
Keypad is cold Massage keypad with fingertips.
Perform keypad test. Refer to diagnostic mode.
Worn faceplate/overlay Replace faulty faceplate/overlay.
Display console Verify 8 VDC and cable and Display Console
connection. See wiring diagram for pin location.
Replace faulty 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
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: DISPLAY CONSOLE INITIALIZES THEN FAILS
Symptom Probable Cause Corrective Action
Display Console initializes
then fails AC Line cord not plugged into
electrical wall outlet Plug AC Line cord into proper electrical outlet.
Unit power switch (I/O) not in
ON position Place power switch in ON (I) position.
Power supply not 115VAC Using a voltmeter, verify power supply is
115VAC.
Loose wire connections, or
wire connectors not seated
properly
Disconnect then reconnect harness
connections at Display Console. See How
To...Remove Display Console.
Disconnect then reconnect all connections. See
How To... Remove Shroud Assembly.
Damage cable Using an ohmmeter, verify continuity of wire
harness. Replace worn or damaged wire
harness.
Display Console Using a voltmeter, verify power at the cable and
Display Console connection. See wiring
diagram for pin location.
10 amp circuit breaker blown Reset 10-amp circuit breaker.
Damaged 10 amp circuit
breaker Using an ohmmeter, verify the circuit breaker is functioning. Replace faulty part.
2 amp circuit breaker blown Reset 2-amp circuit breaker.
Damaged 2 amp circuit
breaker Using an ohmmeter, verify the circuit breaker is functioning. Replace faulty part.
Blown 5 amp slow blown fuse
on Power Control Board Using an ohmmeter, verify 5-amp fuse. Replace faulty part.
Power Control Board Using a voltmeter, verify power at test points.
See How To... Replace Power Control 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
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: ERRATIC DISPLAY CONSOLE LED’s.
Symptom Probable Cause Corrective Action
Display Console LED’s are
not constant AC Line cord not plugged into
electrical wall outlet Plug the AC Line cord into proper electrical outlet.
Unit power switch (I/O) not in
ON position Place the power switch in ON (I) position.
Power supply outlet 115VAC Using a voltmeter, verify power supply is
115VAC.
Loose wire connections, or
wire connectors not seated
properly
Disconnect then reconnect harness
connections at the Display Console. See How
To... Remove Display Console.
Disconnect then reconnect all connections. See
How To... Remove the Shroud Assembly.
Damage cable Using an ohmmeter, verify continuity of wire
harness. Replace the worn or damaged wire
harness.
Display Console Perform Display Test see diagnostic.
Using a voltmeter, verify power at the cable and
Display Console connection. See wiring
diagram for pin location.
Replace faulty display.
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
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
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.”
User over stepping goal pace Users actual pace and goal pace should equal.
Wire connections Disconnect then reconnect all cable
connections. See How To... for removal of
Display Console and Shroud assembly to
check Power Control Board connections.
Check the field wire connection is tight. See
wiring diagram.
Alternator Brushes Perform alternator step height test. Resistance
and load will increase as the field duty cycle
percent increases.
Perform step alternator test. Tension should
increase as INCREASE key is pressed. If
tension does not increase, inspect alternator
brushes. Brushes should not be cracked or less
than 1/4 inch long. Brushes should be of
approximately equal length. Field wire should
be connected.
Replace faulty alternator brushes.
Alternator Perform step height and field duty cycle load.
Replace alternator.
Power Control Board Verify voltage output. See wiring diagram for
location and values.
Replace faulty power control box.
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
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: IMMEDIATE, EXCESSIVE RESISTANCE LOAD DURING PROGRAM
Symptom Probable Cause Corrective Action
Upon start of the program,
excessive resistance load
is immediate; no normal,
incremental increase from
“no load.”
Wire connectors not seated
properly Remove the Display Console and then disconnect and reconnect the harness
connections at the Display Console.
Remove shroud. See How To....
Alternator cable Verify field wire is connected. Use an
ohmmeter to verify cable.
Alternator brushes Perform step alternator test. Tension should
increase as INCREASE key is pressed. If
tension does not increase, inspect alternator
brushes. Brushes should not be cracked or less
than 1/4 inch long. Brushes should be of
approximately equal length. Field wire should
be connected.
Replace faulty alternator brushes.
Alternator Perform field duty cycle test. See diagnostic.
Replace faulty alternator.
Power Control Board (PCB) Using a voltmeter, verify power at test points.
See wiring diagram for voltage outputs and pin
locations
Replace faulty PCB.
Display Console Verify 8 VDC, cable, and Display Console
connections. See wiring diagram for pin
locations.
Replace faulty 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

10
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: INACCURATE COUNT OF STEPS - GOAL OR ACTUAL
Symptom Probable Cause Corrective Action
Upon start program or,
during program, displayed
count of steps is not
accurate.
Display Console Test the display step height. See diagnostics.
Wire connectors not seated
properly Remove the Display Console. Disconnect then reconnect the harness connections at Display
Console. See How To...
See How To... Remove shroud assembly.
Alternator Brushes Perform step alternator test. Tension should
increase as INCREASE key is pressed. If
tension does not increase, inspect alternator
brushes. Brushes should not be cracked or less
than 1/4 inch long. Brushes should be of
approximately equal length. Field wire should
be connected.
Replace faulty alternator brushes.
Alternator Perform step alternator test. Refer to
diagnostic mode.
Replace faulty alternator.
Power Control Board Using a voltmeter, verify test points on Power
Control Board. See wiring diagram for voltage
values and pin locations.
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
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: EXCESSIVE RESISTANCE VARIES DURING PROGRAM
Symptom Probable Cause Corrective Action
During program, excessive
resistance loading occurs. Wire connectors not seated
properly Remove Display Console. Disconnect then reconnect harness connections at Display
Console.
Alternator cable Verify the field wire connector.
Use an ohmmeter to verity cable.
Alternator Perform field duty cycle test. See diagnostic to.
Replace faulty alternator.
Alternator brushes Perform step alternator test. Tension should
increase as INCREASE key is pressed. If
tension does not increase, inspect alternator
brushes. Brushes should not be cracked or less
than 1/4 inch long. Brushes should be of
approximately equal length. Field wire should
be connected.
Replace faulty alternator brushes.
Power Control Board Using a voltmeter, verify power at the points.
See wiring diagram for voltage outputs and pin
location. Replace faulty Power Control Board.
Display Console Verify 8 VDC and cable and Display Console
connection. See wiring diagram for pin location.
Replace faulty 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

12
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: RESISTANCE VARIES DURING PROGRAM
Symptom Probable Cause Corrective Action
During program, resistance
variation occurs. User over stepping goal pace See operation manual for proper operation.
Alternator cable Verify field wire connections. Use an ohmmeter
to verify cable.
Wire connectors not seated
properly Remove Display Console. Disconnect and reconnect the harness connections at Display
Console.
Alternator brushes Perform step alternator test. Tension should
increase as INCREASE key is pressed. If
tension does not increase, inspect alternator
brushes. Brushes should not be cracked or less
than 1/4 inch long. Brushes should be of
approximately equal length. Field wire should
be connected.
Replace faulty alternator brushes.
Alternator Test with substitute alternator. Replace faulty
alternator.
Power Control Board Test with a substitute Power Control Board.
Replace faulty Power Control 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

13
Life Fitness 9100/9500HR Belt Drive Stairclimbers
TROUBLESHOOTING GUIDES
Symptom: DISPLAY HAS NO RPM
Symptom Probable Cause Corrective Action
Unit goes back to “Press
Start to Begin” one minute
into the program
No RPM detected. Verify unit is sensing RPM. See diagnostic
mode.
Verify proper contact on wire harness.
Disconnect and connect cables. See How To...
Remove Display and Shroud Assembly.
Using an ohmmeter, verify continuity. See
wiring diagram for RPM pin location.
Replace faulty cable assembly.
No RPM readout in Display Display LED’s Perform display LED test. See diagnostic.
Replace faulty Display.
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