Life Fitness 9000HR User manual

Models 9000HR, 8500, and T9i Treadmills
Customer Support Services
SERVICE MANUAL

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
INTRODUCTION
This service manual is applicable to Treadmill Models TR9000HR, TR8500, and T9i. Note: Information in this
service manual represents typical configuration and may differ slightly from actual equipment. This manual consists
of the following topics and sections.
INTRODUCTION
SPECIAL SERVICE TOOL REQUIREMENTS
THEORY OF OPERATION
TERMINOLOGY
COMPONENT IDENTIFICATION
TABLE OF CONTENTS
Section I
TROUBLESHOOTING GUIDES
Section II
DIAGNOSTIC MODE
Section III
"How To..." SERVICE AND REPAIR GUIDES
Section IV
ELECTRONIC OVERVIEW
WIRING BLOCK DIAGRAMS
Section V
MISCELLANEOUS INFORMATION
If an operating problem should arise, turn to the TROUBLESHOOTING GUIDES and attempt to isolate what is
causing the malfunction. The GUIDES are listed by symptoms and follow with suggestions as to the most probable
cause of the problem.
Once you have pinpointed the source of the problem, turn to the appropriate "How To..." section and review the
proper procedures for removing, replacing or adjusting a part. The "How To..." sections are organized by
replaceable part (or assembly) name, and under the title of the service procedure will be list only those special
service tools need to perform the task. See next page for Special Service Tool Requirements.
Refer to COMPONENT IDENTIFICATION in the front part of this section to locate and identify in order service
repair parts for your machine.
If you do not have a part in stock, a form to order by FAX has been included in Section V for your convenience or
you can call Life Fitness Customer Support Services any Monday through Friday from 8:00 AM to 5:00 PM central
standard time. To speed-up our response time to your particular situation, please have the following information
available for the customer service phone technician who will be prepared to assist you:
1. Serial number
2. Equipment model number
3. Symptom or problem
4. Part name and number to order
When you receive your order, review the appropriate "How To..." section and follow the step by step procedures
designed to help you install the part quickly and correctly.
If you have any questions or comments please phone, mail, or fax us at:
LIFE FITNESS COMPANY - CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue, Franklin Park, IL 60131; U.S.A.
Telephone: [phone], Toll Free: 800-351-3737, FAX: [phone]

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
SPECIAL SERVICE TOOL REQUIREMENTS
Unless otherwise specified, only basic hand tools are required to perform service procedures
outlined in this section. Some of these standard tools should consist of: Philips and Straight-
Blade Screw Drivers, Torx Set, Pliers, Rubber Mallet, Pry Bar, Snap Ring Pliers (internal and
external), Standard and Metric size Socket Set (3/8 or 1/2 drive), and Standard and Metric size
Combination, open-end, or Box Wrenches.
Specialized tools will be listed after the sub-heading Special Service Tools:, which appears
below the Service Procedure Heading at the top of the page. If no specialized tools are
required, then the title would read: Special Service Tools: NONE, which means that standard
hand tools should be employed to provide service to the product.
Specialized tools must be used to safely and effectively complete the service procedures.
Improvisation or attempts to use any other tool could result in unnecessary damage to the
equipment or personal injury.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
THEORY OF OPERATION
The treadmill is an electromechanical device that operates on 120 volt system and is controlled
through the electronics in the display console. The key components that make up the treadmill
are the unit frame, electric motor and motor controller, belt and deck, wax and wax motor,
pulleys and rollers, and the display console.
Initially, voltage is received by the Line Filter which distributes this power to the motor controller
and other various electrical and electronic components that activates all the mechanical
devices. The operator ultimately controls all electromechanical devices through the console
display, making settings and adjustments to speed, incline, and custom workout programs.
The Unit Frame is critical not only to support the operator but also to support the
electromechanical devices and the unit's overall appearance. Although the frame is a non-
maintenance item, its design and structure are essential to providing years of safe and reliable
service.
The most critical parts on the treadmill are the Belt and Deck. Regardless of all other
components, the success of a good treadmill is its belt and deck. The Deck is made up of a
special particle board which allows for flexibility and long wear. Under the deck are the
lifesprings which are designed to support and absorb the shock load. To prevent the deck from
being worn out by constant operation of the belt, wax is applied to the inside of the belt. This is
accomplished by a wax motor which pumps the wax out of the wax bag and through the wax
nozzle. Remember, when replacing the belt, reverse or replace the deck, and check the anti-
static tinsel.
The Belt is designed to endure constant stress loads. It is mounted directly over the front and
rear rollers. The Main Drive Motor has a pulley on the end of its shaft which is connected by a
drive belt to the pulley on the front roller. When the front roller is driven by the motor the striding
belt moves accordingly. The rear roller is not motor driven but travels along with the current
speed of the front roller. Belt tension is adjustable by means of adjusting bolts which are located
at the ends of the rear roller. When turned, they are used to adjust belt tension and belt
centering. In order to increase belt and deck life, it is important to properly keep clean all areas
of the machine.
The Display Console is the brain center of the treadmill. It is here where all electromechanical
operations are controlled for specific program operations. Depending on the display console,
various selections and settings can be easily accomplished either through a numeric keypad or
up/down arrows. The display console allows the operator to selectively choose the program and
input pertinent statistical information such as weight, age, language, etc.
The treadmill is by far one of the most popular pieces of all cardiovascular exercise equipment.
With proper routine maintenance and care, it will provide a lifetime of healthy cardiovascular
exercise.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TERMINOLOGY
Anti-Scuff Pads Rubber strips located on the surface of each side of the frame, and used to ensure
sure footing.
Anti-Static
Tinsel A copper tinsel wire that discharges static electricity from the striding belt during
operation.
Connectors Plastic devices used to connect wiring together.
Deck Special particle board that is used for the running surface.
Display Console
Board Electronic board used for making direct input settings and monitoring output
messages which are displayed in the digital readout display.
Dynamic Current Current which changes randomly.
EEPROM Electrically erasable programmable read only memory.
EEROM Electrically erasable read only memory.
Front Roller Motor belt driven, the front roller drives the striding belt.
HR & LF Pulse
Sensors Located in each handle grip and measures heart rate.
Jumper Electrical connector used to connect between two electrical points.
LED Light emitting diodes are used to indicate a condition.
Levelers Adjustable supports under the rear of the treadmill, which are used to stabilize the
unit.
Lift Motor The motor that raises and lowers the unit for incline operations.
LifeSprings Springs under the deck to absorb impact of the walker or runner.
Main Drive Belt Connects between the main drive motor pulley and the front roller pulley, and used
to transmit the driving power of the main drive motor to the front roller.

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Life Fitness Models 9000HR, 8500, and T9I Treadmills
TERMINOLOGY
Main Wire
Harness Routed through the left uprights to DC Motor Controller and then, to the control
console.
Heart Rate Wire
Harness Routed through right side of upright.
Motor Controller Receives an output signal from the console display to perform all functions.
Overlay Bezel Plastic covering with key pad which is part of the display console.
PCB Programmable Circuit Board
Line Filter Receives main electrical source from the wall outlet and filters voltage to the DC
Controller for all electromechanical systems.
Polar Receiver Monitors heart rate.
Rear Roller A free spinning roller with adjusting screws at each end of the roller are used for
tensioning and centering the striding belt.
Rear Roller
Guards Located at the back of each side of the rear roller, are used as protective guards.
RPM Revolutions per minute.
Static Current Steady current flow.
Stop Switch A switch used to interrupt power going to the motor to stop the unit.
Striding Belt Sometimes referred to as the 'walking belt' and used to walk or run on.
Telemetry
Receiver A sensor that reads Heart Rate signal transmitted from the operator's chest strap
transmitter.
Ties Plastic straps used to secure loose wiring to the main frame.
Wax Bracket A mounting bracket that spans across the rear width of the unit and is located inside
the striding belt area, is used to secure the positions of the wax tube and wax
nozzle.
Wax Motor This motor is mounted on the frame and is used to pump the wax out of the wax
bag, through the wax tube, and out the wax nozzle onto the underside of the striding
belt.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
COMPONENTS IDENTIFICATION (9000HR Displayed)
Right
Upright
Left
Upright
ERGO
Bar Console
Motor
Cover
End
Cap
Anti-Scuff
Pad
Rear
Roller
Guards
Emergency
Stop
Cup
Holder

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
COMPONENTS IDENTIFICATION
Deck
Deck
Screws
Tensioning
Bolts
Rear
Roller
Front
Roller
Stridin
g
Belt
Deck
Screws
Drive
Motor
Spray Bar &
Nozzle
Wax Motor
Drive
Belt
Life Springs
Leveler

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TABLE OF CONTENTS
SECTION I TROUBLESHOOTING GUIDES PAGE
STRIDING BELT SLIPS DURING FOOTFALL.....................................................................2
MAXIMUM SPEED IS REDUCED.........................................................................................2
KNOCKING SOUND AT REAR OF MACHINE.....................................................................2
KNOCKING SOUND COMING FROM DECK.......................................................................2
STRIDING BELT FOLDS......................................................................................................2
STRIDING BELT TRAVELING BEYOND TRACKING LIMITS.............................................3
STRIDING BELT NOT CENTERED......................................................................................3
STRIDING BELT MISALIGNED............................................................................................3
RUBBING SOUND FROM UNDERNEATH MACHINE.........................................................4
SQUEAKING NOISE.............................................................................................................4
LOUD GROANING SOUND FROM FRONT OF MACHINE.................................................4
LOUD GROANING SOUND ON FOOTFALL........................................................................4
DISPLAY DOES NOT ILLUMINATE WHEN POWERED ON...............................................5
DISPLAY OVERLAY KEYS ARE NOT RESPONDING WHEN PRESSED..........................6
UNIT RESETS RANDOMLY OR PAUSES...........................................................................6
NO POWER..........................................................................................................................7
WAX LEAK............................................................................................................................8
LIFEPULSE HEART RATE DOES NOT RESPOND ............................................................9
EXCESSIVE SWEAT OR CLEANER ON ELECTRODE SENSORS....................................10
DISPLAY READS HEART RATE WITH HANDS REMOVED...............................................10
NO CHEST STRAP DETECTED ..........................................................................................10
ERRATIC HEART RATE READINGS...................................................................................10
SECTION II-A DIAGNOSTIC TR9000HR/T9i
DIAGNOSTIC ENTRY TRHR9000........................................................................................2
DIAGNOSTIC ENTRY T9i.....................................................................................................2
FIRST STATE ON BOTH UNITS..........................................................................................2
SYSTEM TEST .....................................................................................................................3-10
DIAGNOSTICS – INFORMATION........................................................................................11-13
DIAGNOSTICS – MAINTENANCE .......................................................................................14
DIAGNOSTICS – CONFIGURATION...................................................................................15
SECTION II-B DIAGNOSTIC TR8500
DIAGNOSTIC SETTINGS.....................................................................................................18
DIAGNOSTIC MODES..........................................................................................................19
DESCRIPTION.........................................................................................................19
MOTOR TEST..........................................................................................................20
ERROR CODE TROUBLESHOOTING TABLE.......................................................21
INCLINE TEST.........................................................................................................22
WAXER TEST..........................................................................................................22
POLAR TEST...........................................................................................................22
STATISTICS.............................................................................................................22
SETTINGS ...............................................................................................................23
SYSTEM ERRORS..................................................................................................24

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TABLE OF CONTENTS - Continued
SECTION III HOW TO…REPLACE…
STRIDING BELT AND DECK................................................................................................2
TENSIONING STRIDING BELT ...........................................................................................5
ADJUST STRIDING BELT TRACKING ................................................................................6
PERFORM STALL TEST......................................................................................................7
FRONT ROLLER...................................................................................................................8
REAR ROLLER.....................................................................................................................11
DRIVE BELT .........................................................................................................................12
DRIVE MOTOR.....................................................................................................................14
MOTOR BRUSHES...............................................................................................................16
LIFESPRING ABSORBERS..................................................................................................17
WAX NOZZLE.......................................................................................................................19
LIFT MOTOR.........................................................................................................................21
WAX MOTOR........................................................................................................................23
DC CONTROLLER ASSEMBLY...........................................................................................24
ON/OFF SWITCH .................................................................................................................25
WAX BAG – TR8500 INT’L AND TR9000HR DOM/INT’L....................................................26
ANTI-STATIC TINSEL ..........................................................................................................27
ANTI-SCUFF PADS..............................................................................................................28
LEVELER ASSEMBLY..........................................................................................................29
CONTROL BOARD...............................................................................................................30
TETHER, AND THE TELEMETRY RECEIVER AND CABLE...............................................31
MAIN WIRING HARNESS AND ERGO BAR........................................................................32
DOMESTIC AND INTERNATIONAL LINE CORDS..............................................................34
LINE FILTER.........................................................................................................................35
NOTES..................................................................................................................................36
SECTION IV ELECTRONIC OVERVIEW
DISPLAY CONSOLE – TR9000HR/T9i.................................................................................2
DISPLAY CONSOLE – TR8500............................................................................................4
DC CONTROLLER – ALL MODELS.....................................................................................6
BLOCK DIAGRAM ................................................................................................................8
SECTION V – MISCELLANEOUS INFORMATION
PREVENTATIVE MAINTAINENCE TIPS..............................................................................2
INSTALLATION INSTRUCTIONS.........................................................................................3-8

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
NOTES

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
SECTION I
TROUBLESHOOTING GUIDE

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Striding Belt slips during
footfall. Striding belt slips on front roller
during stall test. Check striding belt & re-tension as necessary. See How…To Adjust Belt Tension.
Maximum speed is
reduced. User is pushing striding belt. Instruct users not to push striding belt in either
direction.
Wax system malfunction. Inspect spray pattern between 8" (200mm) and
16" (400mm). Refer to Diagnostics.
If not, verify wax nozzle is clean, hoses are not
kinked, wax bag is not empty, or wax is
contaminated.
Striding belt/deck malfunction.
The deck laminate worn
through or the underside of
striding belt glazed over (hard,
glossy).
Replace belt and deck. See How To…Replace
Striding Belt.
Insufficient power source. Plug treadmill into a dedicated circuit. Refer to
the Operations Manual.
Knocking sound at rear of
machine. Faulty rear roller bearings. Replace rear roller assembly.
Wax build up on rear roller. Run unit for 10 hours to break-in the treadmill.
Knocking sound coming
from deck. Life Springs not positioned
correctly and/or loose mounting
hardware.
Reposition or tighten life springs.
Out of wax. Check wax bag.
Wax Pump failure. Replace pump.
Striding belt folds.
Worn belt or deck. Replace as necessary.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
The Striding Belt is
traveling beyond the
tracking limits.
Striding belt needs to be re-
tensioned or tracking needs
adjustment.
Refer to belt tensioning or tracking adjustment
procedure in operation or service manual.
Worn striding belt or user
pushing belt. Center striding belt according to belt centering technique. See How To...Adjust And Tension
The Striding Belt.
Verify wax in bag. Replace if necessary. See
How To…Replace Wax Bag.
Verify the wax is not contaminated (flakes).
Replace wax bag and wax if contaminated. See
How To…Replace Wax Bag.
Verify the wax nozzle is not clogged. Clean
nozzle if clogged. See How To…Replace Wax
Nozzle.
Refer to “Wax Manual” in the diagnostics
section of this manual to verify if the wax pump
is functioning properly. Replace if necessary.
See How To…Replace Wax Pump.
Striding belt folded over.
Replace the belt and deck. See How To…
Replace Striding Belt. Perform belt and deck
test for wear.
Striding belt not centered. Striding belt tension or tracking
needs to be adjusted. Adjust striding belt . See How To…Adjust And Tension The Striding Belt.
Striding belt mis-alignment,
but properly tensioned. Improper walking/running. Verify unit is level. Notify Club Manager.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Rubbing sound from
underneath machine. Foreign objects may be stuck
underneath the machine. Inspect underneath striding belt and machine. Remove any debris or objects that may cause
interference with the treadmill.
Tinsel is installed incorrectly. Reposition tinsel on the outside of the striding
belt.
Wax bracket loose or missing. Inspect wax bracket underneath deck and
verify wax bracket is secure. See How To…
Squeaking noise. Drive pulley making contact
with frame. Inspect setscrew. If loose, apply 242 Loctite and retighten.
Drive motor belt may be worn
or damaged. Replace faulty drive motor belt. See How To…
Loud groaning sound
heard from front of
machine while elevating.
Lift mechanism pivot points are
dry. Lubricate pivot points.
Lift screw dirty or gummy. Clean and lubricate threaded screw.
Faulty lift motor or lift screw nut
stripped. Replace the lift motor. See How To…Replace Lift Motor.
Loud groaning on footfall. High friction between deck and
striding belt. Refer to belt and deck test in diagnostics.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Display does not illuminate
when machine is powered
on.
Insufficient power source. Plug treadmill into a dedicated amp circuit.
Refer To The Operations Manual.
Loose 10 pin connection at
display console or DC control
board.
Check all electrical connections for proper
attachment. Refer to wiring block diagram in
section 5.
Damaged main harness wire
connection. Replace wire harness. See How To…Replace Main Wire Harness.
Faulty display console. Verify if 8VDC is present at P1 pin, 3-4 and
12VDC at P1 pin 9.
If yes, replace Display Console. See How To…
Replace Display Console PCB.
If no, replace the Control Board. See How To…
in section 3.
Damaged main cable. Perform continuity test from pin connector to
pin connector, and then from connector pins to
frame.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Display overlay keys are
not responding when
depressed.
Loose ribbon connection(s). Verify that the ribbon connections is attached to
the display PCB.
Reseat the connection and verify the operation.
Worn or defective overlay
assembly. Replace overlay assembly. See How To… Replace Overlay Decal.
Unit resets randomly or
pauses. Insufficient power source. Plug treadmill into a dedicated amp circuit.
Refer to the Operations Manual.
Damaged ground prong on line
cord. Replace line cord. See How To… Replace Line Cord.
Loose connections at display
console. Secure all connections at display console PCB.
Line cord improperly seated in
electrical outlet. Inspect power connection at electrical outlet and at machine for proper contact.
Emergency stop magnet not
engaged. Re-engage the emergency stop magnet.
Magazine making contact with
stop key on the overlay Move all possible obstructions off the console and handlebar.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Unit resets randomly or
pauses. Emergency stop switch magnet
not making proper contact. Re-seat the emergency stop switch magnet and verify the operation.
Pinched main wire harness. Replace the main wire harness. See How
To…Replace Main Wire Harness.
Open ground path. Using voltmeter, check all points for continuity:
console pan screws, console mounting screws,
handlebar screws, and handrail mounting
screws to frame with respect to ground. Ground
must be a non-painted surface.
Lift motor over-heating which
causes unit to pause. Inspect thread screw for dirt. Perform lift motor test. Refer to diagnostics.
No Power. On/Off switch. Turn the switch to the ON position.
Insufficient power source. Plug treadmill into a dedicated amp circuit.
Refer to the Operations Manual.
Using a voltmeter, verify power at outlet. If no
power exists, reset circuit breaker at panel.
Damaged line cord. Replace line cord. See How To…Replace Line
Cord.
Line cord improperly seated in
socket. Inspect power connection at wall outlet and at machine for proper contact.
No line filter. Verify voltage at the line filter.
Verify 120VAC at the control connector P1.
Refer to Service Manual, Section 4 Electronics.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
No Power. DC Controller Turn the switch to the ON position.
Verify at P3, 8VDC on Pins 3 and 4. Refer to
Service Manual, Section 4 Electronics.
Verify at P3, for 12VDC on Pin 9. Refer to
Service Manual, Section 4 Electronics.
Verify both LEDs 5 and 6 are lit. Refer to
Service Manual, Section 4 Electronics.
Wax Leak. Loose hose connections. Inspect hose connections and secure as
necessary, replace if necessary.
Faulty connection at bag. Replace wax bag and plastic coupling.
Wax bag is torn. Replace wax bag. See How To…Replace Wax
Bag.
Wax hose damaged. Inspect for leaks and replace.
Wax hose in pump is
damaged. Inspect wax hose.
Wax passes through pump
and slowly drips from nozzle. Replace wax motor. See How To…Replace Wax Motor.

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Life Fitness Models 9000HR, 8500, and T9i Treadmills
TROUBLESHOOTING GUIDE
Malfunction Probable Cause Corrective Action
Dirty handlebar sensors. Wipe sensors with a clean soft cloth.
Lifepulse Heart Rate System
does not respond or
improper heart rate reading
or "Reading Heart Rate"
appears in the message
center for more than 2
minutes without giving heart
rate reading.
Inadequate contact with all four
sensors. Verify a firm grip of all four sensors (two on top, two on bottom of handlebar).
User running over 4.5 mph
(7.5kph). For accurate heart rate reading, user must slow down to less than 4.5 mph (7.5kph).
User may have an unusual
heart condition. Have different people grasp sensors to detect any variance.
Loose connections at display
console and handlebar. Secure connections at display console and handlebar.
Faulty heart rate sensors.. Replace handlebar sensors. See How To…
Replace Heart Rate Kit.
Faulty display console PCB. Replace display console PCB. See How To…
Replace Display Console PCB.