Life Fitness 9100 User manual

9100 Series Heartrate and Telemetry Equipped Treadmills
Customer Support Services
SERVICE MANUAL

Life Fitness 9100 Series Heartrate and Telemetry Equipped Treadmills
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL
In the unlikely event that an operating problem may occur with your Life Fitness model 9100 aerobic trainer,
this Service Manual will instruct and guide you on the quickest, most efficient manner in which to approach
the situation. This Service Manual has been separated into a total of Five Sections for quick reference:
INTRODUCTION
TABLE OF CONTENTS
Section I
TROUBLESHOOTING GUIDES
Section II
DIAGNOSTIC TESTS
Section III
MODEL 9100 "How To..." GUIDES
Section IV
PARTS IDENTIFICATION
Section V
WIRING DIAGRAMS
PREVENTIVE MAINTENANCE
COMMUNICATING BY FAX
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 each page lists the “Tools Required“ to complete that specific
function. Refer to Section IV to identify the proper name and number of the part you will now need to order
to repair your machine. A form to order by FAX has also been included in Section V for your convenience.
To order a part, call Life Fitness Customer Support Services any Monday through Friday from 8:00 AM to
6:00 PM ( C.S.T.). When you place a call, in order to speed our response to your particular situation, please
have the following information available for the customer service phone technician who will be prepared to
assist you:
1. The Treadmill model type
2. The serial number ( Located on the crossbar of the lift mechanism)
3. The symptom of the problem you are experiencing
4. The part name and number you need 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 one of the numbers listed below.
CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue, Franklin Park, IL 60131
Phone ( 800 ) 351-3737 Toll Free or [phone] FAX [phone] Toll Free or [phone]
Serial Number:

Life Fitness 9100 Series Heartrate and Telemetry Equipped Treadmills
TABLE OF CONTENTS
Introduction (How To Use This Service Manual)
Table of Contents
SECTION I Page
Troubleshooting Guides
Belt Slips Or Display Reads Error....................................................................................................1
Display Will Not Program Password Or Locked In Password Mode.............................................2
Noisy Treadmill..................................................................................................................................3
Display Does Not Illuminate Or Respond To Input ........................................................................4
Unit Resets Randomly ......................................................................................................................5
No Power............................................................................................................................................6
Wax Will Not Fill Properly.................................................................................................................7
Wax Is Leaking From Treadmill .......................................................................................................8
Striding Belt Comes In Contact With Frame And End Caps..........................................................9
Display Reads “Notify Maintenance” - “Speed Control Error” .....................................................10
Striding belt Not Centered On Deck ................................................................................................11
Lift Error.............................................................................................................................................12
Display Reads “Notify Maintenance” - “Waxer Disconnect” ........................................................13
Heart Rate System (If Equipped With Optional Heart Rate Kit).....................................................14
No Telemetry Reading ......................................................................................................................15
SECTION II
Diagnostic Tests..............................................................................................................................................1-4
SECTION III
How To...REMOVE AND REPLACE THE
Anti-Scuff Pads..................................................................................................................................2
Debris Brush......................................................................................................................................3
Anti-Static Cords...............................................................................................................................4
Deck....................................................................................................................................................5,6
Transformer.......................................................................................................................................7
Lifesprings.........................................................................................................................................8
PC Control Board ..............................................................................................................................9,10
Display Console ................................................................................................................................11
Stop Switch........................................................................................................................................12
Telemetry / HR Kit .............................................................................................................................13
Handrails............................................................................................................................................14
Handlebar...........................................................................................................................................15
Wax Motor/Pump Assembly.............................................................................................................16
Drive Motor.........................................................................................................................................17,18
Separate the Front and Rear Frame Assemblies............................................................................19,20
Striding Belt.......................................................................................................................................21,22
Lift Actuator.......................................................................................................................................23
Motor Controller ................................................................................................................................24
Rear Roller.........................................................................................................................................25
Power Box..........................................................................................................................................26
Wax Container...................................................................................................................................27,28
Front Roller........................................................................................................................................29,30
Drive Motor Belt.................................................................................................................................31,32
How To...ADJUST AND TENSION THE STRIDING BELT.............................................................................33-36
ADJUST AND TENSION THE LIFT ACTUATOR...............................................................................37
SECTION IV
Parts Identification ..........................................................................................................................................1-5
SECTION V
Wiring Diagram................................................................................................................................................1
Preventive Maintenance Tips .........................................................................................................................2
Communicating By Fax...................................................................................................................................3,4

©1997 Life Fitness. All rights reserved. The Life Fitness trademark is register in the U.S. Patent and Trademark Office,
Certificate No. 1,400,502, issued July 8, 1986. FlexDeck, Zone Trainer and Heart Rate Zone Training are trademarks of
Life Fitness. Any use of these trademarks, without the express written consent of Life Fitness, is forbidden.
U.S. Patent Numbers 3,767,195 and 4,358,105.
M051-00K26-A231
7-97

1
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: "Slowdown". Striding Belt slips during footfall or display reads "Press Start
to Resume", or "Note Max. Speed Is Reduced To".
Malfunction Probable Cause Corrective Action
Striding Belt slips during
footfall
Maximum speed is reduced
Striding belt slips on front roller
during stall test.
Insufficient power source.
User is pushing striding belt.
Wax system malfunction.
•is spray pattern between 8"
(200mm) and 16" (400mm)?
•is nozzle clean?
•is hose kinked?
•is wax bag empty?
•Is there a wax leak?
•is the wax contaminated?
•is manual waxing used?
Striding belt/deck malfunction:
•Deck laminate is worn
through.
•Underside of striding belt is
glazed over (hard, glossy)
•There is a large build-up of
wax, excessive wax fills
fingernails when scratching
underside of belt.
Check striding belt & re-tension as
necessary.
Plug treadmill into a dedicated 120V, 20
amp circuit. (See Operation Manual)
Inspect striding belt and deck for excessive
wear. Replace any defective part.
Inspect striding belt and deck for excessive
wear. Replace any defective part.
Replace deck and belt (Use unused side of
deck, if available).
For 9100 with Telemetry only, reset stats & turn
wax delay ON.
For 9100HR, update service menu.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

2
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Display Will Not Program Password or Locked In Password Mode
Malfunction Probable Cause Corrective Action
Display will not accept
password entries
Locked in password mode
Incorrect entries
Pressing 0 as an entry.
Incorrect password entered.
Enter new password.
Incorrect entries.
Only 3 digits are acceptable as a password
(entries 1 through 999).
Pressing 0 before pressing other numeric
keys will disable the password protection
program.
Press CLEAR twice.
Press 9100 ENTER for access to password
mode.
Enter new password. A valid password is 3
digits: 1 through 999.
Press ENTER.
Press CLEAR twice.
Press 9100 ENTER for access to password
mode.
Press 0 then CLEAR to reset password
mode.
Press ENTER.
Call Life Fitness Custromer Support Services
847-451-0036 or 1-800-351-3737

3
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Noisy Treadmill
Malfunction Probable Cause Corrective Action
Knocking sound at rear of
machine
Knocking sound coming
from deck
Rubbing sound from
underneath machine
Squeaking noise
Loud "groaning" sound
heard from front of
machine while elevating
Loud "groaning" on footfall
Loud rumble between 2.5
and 3.0 mph
Faulty rear roller bearings.
Wax build up on rear roller.
Worn lord mount or loose.
Foreign objects may be stuck
underneath the machine.
Rear tinsel guard may be bent.
Rear roller guard may be bent,
broken or not secured.
Tec packs may be out of
alignment.
Damaged deck stiffener.
Drive motor belt may be worn
or damaged.
Drive motor belt tensioning pin
may be squeaking.
Faulty lift actuator.
High friction between deck and
striding belt
Faulty motor controller
Replace rear roller assembly.
Run unit for 10 hours to burn in.
Replace or tighten 4 lord mounts.
Inspect underneath striding belt and
machine. Remove any debris or
accumulation on debris brush.
Bend guard away from belt, or replace if
damaged.
Re-attach or replace guard.
Reposition Tec packs.
Reposition or replace old style deck
stiffener.
Replace drive motor belt.
Spray pin with lubricant.
Replace lift actuator.
Refer to slowdown section.
Replace motor controller.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

4
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Display Does Not Illuminate or Respond To Input
Malfunction Probable Cause Corrective Action
Display does not illuminate
when machine is powered
on.
Insufficient power source.
Pinched wire connection
Loose connection at display
console or control board.
Faulty CPU control board.
Faulty display console.
Plug treadmill into a dedicated 120V, 20
amp circuit
Turn power off for 30 seconds. Turn power
on and within 30 seconds of turning on
press "9-0-9" on the keypad.
Check all electrical connections.
Check all electrical connections.
Secure connections at display console and
control board.
Switch CPU control board with another Life
Fitness model 9100 treadmill if available.
Replace CPU control board.
Switch display console with another Life
Fitness model 9100 treadmill if available.
Replace display console.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

5
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Unit Resets Randomly
Malfunction Probable Cause Corrective Action
Unit resets randomly
Unit resets intermittently
Insufficient power source.
Damaged ground prong on line
cord.
Line cord improperly seated in
electrical outlet.
Loose connections at CPU
control board and display.
Towel or magazine may be
making contact with stop
switch while user is running.
Stop switch cover is missing.
Stop switch is activated with
very light pressure or returns
very slowly after being pressed.
Stop switch cable not making
proper contact
Pinched display console
harness
Open ground path
Display reads “Power up reset”
Plug treadmill into a dedicated 120V, 20
amp circuit.
Replace line cord.
Inspect power connection at electrical
outlet and at machine for proper contact.
Secure connections at CPU control board
and display.
Move possible obstructions off display
console and handlebar.
Replace stop switch/or console.
Replace stop switch/or console.
Reseat cable from stop switch.
Check all display console connections.
Using voltmeter, check 4 points for
continuity: console pan screws, console
mounting screws, handlebar screws, and
handrail mounting screws to frame with
respect to ground. Ground must ba a non-
painted surface.
Verify power is a dedicated outlet. To verify,
turn breaker at panel to off. Using a
voltmeter, take a voltage reading at
electrical outlet. With breaker off, zero volts
should be detected.
If voltage is present at electrical outlet, line
is not wired for dedicated service.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

6
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: No Power
Malfunction Probable Cause Corrective Action
No Power
Insufficient power
On/Off switch.
Insufficient power source.
Damaged line cord.
Line cord improperly seated in
socket.
Faulty display console.
Power module.
•Circuit breakers
•On/Off switch
Interrupted circuit.
Display reads “Power up reset”
Is unit turned on?
Plug treadmill into a dedicated 120V, 20
amp circuit.
Using a meter, verify power at outlet.
Replace line cord.
Inspect power connection at wall outlet and
at machine for proper contact.
See "Display Console" symptom.
Check connector P4 at CPU board for
120VAC.
Replace faulty parts
Test circuit breaker on treadmill. Replace if
necessary.
Verify power is a dedicated outlet. To verify,
turn breaker at panel to off. Using a
voltmeter, take a voltage reading at
electrical outlet. With breaker off, zero volts
should be detected.
If voltage is present at electrical outlet, line
is not wired for dedicated service.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

7
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Wax Will Not Fill Properly
Malfunction Probable Cause Corrective Action
Wax will not fill Fill valve in kit has crimped fill
hose.
Fill valve in treadmill is not fully
open.
Fill hose in treadmill is crimped.
Check the fill valve for proper operation.
Check the fill hose for kinks, straighten as
necessary.
Check T-connector for blockage.
Check fill valve in treadmill for proper
operation.
Check the fill hose for kinks, straighten as
necessary.
Lightly squeeze wax container.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

8
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Wax Is Leaking From Treadmill
Malfunction Probable Cause Corrective Action
Wax Leak Partially open or faulty fill valve.
Loose hose connections.
Faulty connection at "T" fitting
and bag.
Wax bag is torn.
Wax pump does not shut off.
Wax passes through pump and
slowly drips from nozzle
Fully close fill valve.
Inspect hose connections and secure as
necessary.
Replace if necessary.
Replace wax bag and all tubing.
Replace wax bag.
Replace wax pump.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

9
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Striding Belt Comes In Contact With Frame and End Caps
Malfunction Probable Cause Corrective Action
The Striding Belt is traveling
beyond the tracking limits. Worn striding belt or user
pushing belt.
Striding belt needs to be
re-tensioned.
Striding belt folded over
Center striding belt according to belt
centering technique (See “How
To...Adjust and Tension the Striding
Belt”).
Refer to belt tensioning procedure in
operation or service manual.
Verify wax in bag
Verify the wax is not contaminated
(appears lumpy). Replace wax bag and
wax if contaminated.
Verify the wax nozzle is not clogged.
Clean nozzle if clogged.
Verify the wax pump is functioning
properly. Replace if necessary.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737
NOTE: Also refer to Symptom: "Slowdown" and "Striding Belt Not Centered On Deck".

10
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: "Notify Maintenance" - "Speed Control Error"
Malfunction Probable Cause Corrective Action
Speed control error Faulty Power
Loose connections at motor
controller.
Faulty Emerson motor
controller.
Faulty CPU control board.
Faulty drive motor assembly.
Verify power is a dedicated outlet. To
verify, turn breaker at panel to off. Using a
voltmeter, take a voltage reading at
electrical outlet. With breaker off, zero
volts should be detected.
If voltage is present at electrical outlet,
line is not wired for dedicated service.
Record speed error #, and refer to
maintenance mode in diagnostics.
Start speed diagnostics. If "Total Cal" and
"Cal/HR" LED's are not lit, inspect wire
connections at control board and motor
controller. Check connections.
If "Total Cal" LED is lit and "Cal/HR" LED
is out, then with your feet off the striding
belt, press the speed increase key. The
"Total Cal" LED should go out initially
while the "Cal/HR" LED comes on. Once
the belt reaches speed, both LEDs should
be on. If this is the case, both the control
board and the motor controller are
functioning, complete the Speed
Performance Evaluation.
Switch the Emerson motor controller with
another Life Fitness model 9100
treadmill, if available.
Replace motor controller.
Switch the CPU control board with
another Life Fitness model 9100 treadmill
if available.
Replace control board.
Inspect main drive motor and drive belt.
Replace if necessary.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737

11
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Striding Belt Not Centered On Deck
Malfunction Probable Cause Corrective Action
Striding belt mis-alignment
Striding belt not centered
Improper walking/running.
Striding belt tension needs to
be adjusted. See How To... Adjust and Tension the Striding Belt
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737
NOTE: Also refer to Symptom: "Belt Beyond Limits" or "Notify Maintenance-Belt Tracking Error"

12
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Display reads "Notify Maintenance Lift Control Error"
Malfunction Probable Cause Corrective Action
Lift Error Unit intermittently stuck in up
position
Jammed in up position, 3 amp
breaker popped
Unit will not lift, 3 amp breaker
popped
Incline control error.
Insufficient power source.
Weight limitation.
Will not lift.
3amp circuit breaker popped.
Failed, damaged or cracked lift
actuator.
Press 9-1-9 ENTER, press INCLINE down
button.
Check all connections on CPU control board,
check for presence of suppresser board.
Replace CPU control board and suppresser
board.
Check 3 amp breaker.
Check all connections, replace CPU board
and suppresser board.
Reset 3 amp breaker.
Press 9-1-9 ENTER, press INCLINE down
button.
Check all connections on CPU control board,
check suppresser board.
Check home switch for smooth operation and
check home switch cables/connections.
Replace if necessary. Re-test.
Press 9-1-9 ENTER, perform IA test
procedure (two person test)
Verify power is a dedicated outlet. To verify,
turn breaker at panel to off. Using a voltmeter,
take a voltage reading at electrical outlet.
With breaker off, zero volts should be
detected.
If voltage is present at electrical outlet, line is
not wired for dedicated service.
Plug treadmill into a dedicated 120v, 20amp
circuit. (See Operation Manual)
Advise user of weight limit.
Perform IA test procedure.
Check home switch for smooth operation and
check home switch cables/ connectors.
Check lift actuator cable connections and
presence of (1 only) suppresser board.
Test circuit breakers. Replace if necessary.
Replace lift actuator.
Call Life Fitness Customer Support Services
847-451-0036 or 1-800-351-3737
*All treadmills require a 120v 20amp dedicated line.

13
Life Fitness 9100 Series Heart Rate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Display reads "Notify Maintenance” “Waxer Disconnect"
Malfunction Probable Cause Corrective Action
Waxer
Disconnect Wax assembly electrical line cord
3 amp breaker popped / faulty
Faulty CPU Control Board
Verify waxer cable is plugged into
electrical outlet on front frame assembly.
Using an Ohm Meter, check continuity on
waxer cable and plug
Check 3 amp breaker.
Test circuit breakers. Replace if
necessary.
Swap CPU with another 9100 model
treadmill. Replace CPU control board
Call Life Fitness Customer Support
Services
847-451-0036 or 1-800-351-3737
*All treadmills (U.S. and Canada) require a 120v 20amp dedicated line.

14
Life Fitness 9100 Series Heartrate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: Lifepulse Heart Rate System Does Not Respond, Erratic Heart Rate Reading
Malfunction Probable Cause Corrective Action
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.
Display reads a continuous
heartrate reading when
hands are removed.
Dirty handlebar sensors.
Inadequate contact with all four
sensors.
User running over 4.5 mph
(7.25kph).
User may have an unusual
heart condition.
Older software version on heart
rate sensor board.
Loose connections at display
console and handlebar.
Faulty display console.
Faulty handlebar.
Sweat trails or cleaner residue
will cause misreadings.
Harness wires pinched at
handlebar or handrail.
Wipe sensors with a clean soft cloth.
Verify a firm grip of all four sensors (2 on
top, 2 on bottom of handlebar).
For accurate heart rate reading, user
must slow down to less than 4.5 mph
(7.5kph).
Have different people grasp sensors to
detect any variance.
Enter into DIAGNOSTIC menu to attain
software version. Enter into Execute
Viewing of Usage Statistics.
Secure connections at display console
and handlebar.
Replace entire display console.
Swap handlebar with known working
machine. Replace handlebar if
necessary.
Clean sensor with water and a clean soft
cloth to remove salt and oils.
±Replace handlebar if the wires are
damaged.
.
Call Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737
*HR rates begin at 70.

15
Life Fitness 9100 Series Heartrate and Telemetry Equipped Treadmills
TROUBLESHOOTING GUIDE
Symptom: NO TELEMETRY READING
Malfunction Probable Cause Corrective Action
No Chest Strap detected.
Erratic Heart Rate readings
(Cross Talk)
Display reads “Chest strap
not Detected”
Chest strap sensors not making
good contact with body of user.
Loose connection at receiver.
User is out of monitoring range.
Faulty receiver.
Faulty chest strap.
Treadmills are located less than
8” (203 mm) apart.
Telemetry turned “OFF”
Receiver is turned slightly
sideways
Bad connection at Telemetry
cable and receiver
Bad connection at console
Receiver is 180° out of position
Adjust chest strap
Moisten sensors to make better contact
with skin
Check connection on receiver (See “How
To...”)
Move within three feet (1 meter) of
receiver
Replace receiver
Replace chest strap
Position treadmills to recommended
distances (See Operation Manual)
Enter EA mode and turn telemetry to
“ON”
Position receiver so it is horizontal with
the console. (See “How To...Remove and
Replace the Telemetry / HR Unit”)
Check cable jack and receiver
connection.
Reseat telemetry cable at console PCB.
Turn receiver 180°
Call Life Fitness Customer Support Services
1-847-451-0036 or 1-800-351-3737

16
Life Fitness 9100 Series Heartrate and Telemetry Equipped Treadmills
NOTES: