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SERVICE MANUAL - Used Fitness Equipment

1. KKI Y HEART RATE Quick Start ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP E EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout KE x nu ATTENTION CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL im FS FE yu ARRETEZVOUS 51 VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ aip appaga E FAIBLE TOURDI OU COURT DE SOUFFLE mua Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 To select the appropriate default press the UP DOWN ARROW keys until the message TOGGLE DISABLED WATTS TOGGLE ON CAL HR TOGGLE ON or CAL HR WTTS is displayed These are different options the customer can select to have the display console toggle from one item to another Press the CLEAR key to return to Diagnostic State 14 Press the ENTER key to advance to Diagnostic State 16 21 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 16 PHOTOSHOOT Level Calories 28 45 3d 312 O Heart Rate Cal Hour Distance Watts 522 Aerobics Reverse Mode Mode HEART RATE Quick Start CAUTI ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Pa 5 Press Quick Workout m um ATTENTI ON CONSULTEZ UN M DECIN AVANT D UTILISER CE
2. Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 The PROGRAM VERSION NUMBER for 68HC05 micro controller code version will be displayed in the elapsed time window e g P 0 The PROGRAM VERSION NUMBER for HEART RATE DSP Board will be displayed in the speed window 0 The status of the LIFELINK board LIFECENTER connection will be displayed the CALORIES window following message will be displayed NONE No LIFELINK board detected NULL Board detected but not communicating ON Online status with Life Center OFF Offline status with Life Center Press the CLEAR key to return to Diagnostics State 4 Press the ENTER key to advance to Diagnostics State 6 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 5 LIFEPULSE TEST DISPLAY LOCK EQUIPPED MODEL ONLY Heart Rate Cal Hour Distance Watts Calories WHEART RATE Quick Start Press Start Press Quick Workout Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 Life Fitness UK 44 0 1353 666017 Upon initial entry to this test a message concerning the configuration of the lifepulse system being On or Off This test will allow the user to test the lifepulse heart rate system Following this message the lifepulse system can be manually tested A heart will be in the profile window The system will show when
3. 20 DIAGNOSTIC STATE 16 5 21 DIAGNOSTIC STATE 16 LANQUAGE CONFIGURATION DISPLAY LOCK EQUIPPED MODEL 22 DIAGNOSTIC STATE 17 PHOTOSHOOT DISPLAY LOCK EQUIPPED MODEL 23 Life Fitness Models 8500 9100 9500HR Cross Trainers TABLE OF CONTENTS Continued SECTION III HOW TO REPLACE THE DISPLAY CONSOLE n feeit tbt tp ita dea Dra de etie deed 2 ACCESSORY TRAY OPTIONAL ON 8500 3 DISPLAY CONSOLE SUPPORT 4 REAR COVERS uice te T dee uu cec E mnis ar cates 5 CRANKARM ROLLER ASSEMBLY AND 6 CRANKARM ASSEMBLY eine ette ede testen i aer ind 7 DRIVE BELT AND ALTERNATOR 8 POWER CONTROL BOARD 9 ALTERNATOR a sation catia eur cade tue cu Deque sees 10 ALTERNATOR BELT ihnen tete nte e ERR e ease cadena i 11 PEDAL LEEVER ASSEMBLY eee e cte oem tenue ute RR c M I 12 5 Ede ed cda 13 TIE ROD ed Len dag 14
4. 9500HR Cross Trainers How To Replace The Battery Tools required Phillips magnetic screwdriver 2 1 Remove the FRONT COVER screws 6 and separate the front cover halves 2 Disconnect the BATTERY CABLES 3 Remove the battery mounting screws 2 and lift out the BATTERY 4 Install new battery in reverse order Battery Battery Cables 23 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Rear Wheels and Axle Tools required Slotted screwdriver and Pliers 1 Remove the AXLE CAP from the WHEEL AXLE 2 Remove the WHEELS and AXLE 3 Install new wheels axle and axle cap in the reverse direction Wheel 24 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Endcaps Tools required Slotted screwdriver 1 Remove the endcaps from the LOWER ARMS 2 Remove the endcaps from the FRAME 3 Install new endcaps in reverse order Endcaps 25 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Pedal Tools required Clean cloth water and isopropyl alcohol T 2 26 Remove the pedals from the pedal arm assemblies Remove old tape Using a clean cloth carefully clean the surface areas using a misture of 5096 water and 5096 isopropyl alcohol Make sure all adhesive is removed from the pedal and pedal arm assembly and make sure that surface areas are perfectly dri
5. OS VY HEART RATE Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH ATTENTION CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL ae Press Quick Workout 4 42 ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ FAIBLE ETOURDI OU A COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 If BATTERY is selected then SHUTDOWN TIME must be set The SHUTDOWN TIME BATTERY only is set in seconds from 1 to 60 The time specified will shut off the Cross Trainer when no RPMs are detected Pressing the CLEAR PAUSE key will return to Diagnostics State 9 Pressing the ENTER key will advance to Diagnostics State 11 Life Fitness Model 8500 9100 and 9500HR Cross Trainers DIAGNOSTIC STATE 11 PROGRAM TIME Level Heart Rate Cal Hour Time RPM Calories Distance Watts PROGRAM TIME 60 wx Lock Sc aye Y HEART RATE 10 20 30 40 50 60 70 8 90100 Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH ATTENTION CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL PeRAR Press Quick Workout Cr beeen rer dy ARR TEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTE
6. m uL Mu 16 D Resistor Bra c ket Assembly PCB GK61 00002 0024 GK61 00002 0023 Altemator Cable Stand Off 4 AK61 00017 0000 0017 00042 0320 Nut 4 0017 00103 0008 Anti Lift Brac ket 2 0 61 04114 0000 Pillow Bloc k Bearings 2 SN 100000 Up Bol 0017 00101 1646 Nut 0017 00103 0137 Seeve 0K61 01076 0000 Pedal 2 GK61 00002 0010 Tape 4 0K61 04115 0002 0017 00101 1645 Frame Cover GK61 00002 0019 Tape 0K61 04115 0002 Battery 0017 00003 0685 e Zoot rommet 14 0017 00042 0754 Crank Cover 2 0K41 031 00 0000 Crank Am Assembly GK61 00002 0021 Nut 0017 00103 0025 Bolt 0017 00101 1606 Keyway 0K53 01122 0000 Allen Screws 0017 00101 0333 Life Fitness Model 9500 Cross Trainers MODEL CT95 0100 15 SN 100000 Up Polar Cable AK61 00014 0000 Main Cable AK61 00015 0000 Overlay 61 00054 0001 Eng Met Dec ai 5 Console 61 00053 0001 Eng Met HR Cable AK61 00052 0002 0 61 01200 0000 Accessory GK61 00002 0002 Upper Arm RT fort Post Cover 0 61 06350 0002 Upper Arm LT Rear Post Cover AK61 00048 0002 0K61 06351 0002 Polar Receiver Grips 2 SK40 00045 0001 0K61 05008 0000 Foam Insulator 61 00049 0000 _ Pedal Arm Covers RT 0 61 06320 0001 Inside AK61 00018 0003 Outside AK61 00050 0000 Front Boot Cover Pedal Arm RT 0K61 06340 0002 GK61 00002 0006 Plug 2 Rear Boot
7. CRANKSHAFT PULLEY 5 15 dere ter ee incid Ede ere be aes 16 LOAD RESISTORS e AEN AR 17 UIN IET 18 POLAR BRECEIVER ne 19 nune inn cin inei petu ee Ei 20 FRAME GOVER t eed e 21 FRONT COVER cete ete te det cea detta cad 22 ie i Eze ted boh edet eue 23 REAR WHEELS AND AXLE eite ts C temen d d 24 EEUU 25 26 SET JUMPERS ON CSAFE CARD 27 NOTES erit ett pi kino bett hes Beth habete staeeghenitnehetetansinebachehettton 28 SECTION IV ELECTRONICS OVERVIEW WIRING DIAGRAM DISPLAY CONSOLE 2 POWER CONTROL BOARD iiaii eatis terae de eese bed doe 4 ALTERNATOR ergai eet itin ra eere og ed d active Lo deed dg ea 5 WIRING BLOCK 6 Life Fitness Models 8500 9100 9500HR Cross Trainers TABLE OF CONTENTS Continued SECTION V PARTS
8. ConnectorP3 Connector P1 Connector and Pin Functions Connector Location Functional Description P1 is a Molex 11 pin connector that connects to the Console 9 VBAT VDC 0 P2 is 12 pin connector that connects to the Alternator and Bower 6 FIELD 8 LOAD 9 LOAD P3 is 4 pin connector not used 7 8VDC 2 Keyed 21 Life Fitness Model 8500 9100 and 9500HR Cross Trainers ELECTRONICS OVERVIEW ALTERNATOR Functional Description The 12 volt 35 amp Alternator is designed to provide electrical power to the product supply load resistance while providing electrical power and provide the RPM signal from the AC TAP to the Alternator Control Board Connector Locations GROUND TERMINAE Life Fitness Model 8500 9100 9500HR Cross Trainers WIRING BLOCK DIAGRAM FOR LC9500HR 1 THH HT Ld pie Life Fitness Model 8500 9100 9500HR Cross Trainers NOTES o Life Fitness Models 8500 9100 9500HR Cross Trainers SECTION V PARTS IDENTIFICATION gt c 2 o Life Fitness Model 8500 9100 9500HR Cross Trainers MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Model Serial number Life Fitness Model 8500 Cross Trainer MODEL CT85 0100 01 SN 100000 Up Console Post Assembly Console AK61 00500 0005 AK61 00
9. Press the DOWN ARROW to turn OFF telemetry and the UP ARROW to turn it back ON A heart shape illuminates in the program profile window The ENTER key LED illuminates to indicate when TELEMETRY ON This value is stored in EEROM while the cross trainer is not in use Press the CLEAR key to return to Diagnostic State 6 Press the ENTER key to advance to Diagnostic State 8 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 8 ENGLISH OR METRIC UNITS Level Calories Heart Rate Cal Hour RPM Distance Watts ENGLISH UNITS oo c VY HEART RATE 10 20 30 40 50 60 70 80 90 100 R AGE Quick Start ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP E EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH ON CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL PLA LA Press Quick Workout Gi ARRETE OUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ ETT PaT FAIBLE TOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 ENGLISH or METRIC units can be selected Press the DOWN ARROW to select METRIC units Press the UP ARROW to select ENGLISH The ENTER key LED illuminates when defaulted to ENGLISH UNITS This value is stored in EEROM and is kept when the cross trainer is not in use Press the CLEAR key to return to Diagnostic State 7 Press the
10. Verify that magnet is on crank pulley If magnet is not present reinstall magnet Faulty reed switch or board Perform a continuity test Inspect reed switch for damage If necessary replace the board Dead battery after C Safe card is Replace battery if under 5 VDC and installed reset jumpers in C Safe card See How To Set Jumpers Life Fitness Model 8500 9100 9500HR Cross Trainers NOTES Life Fitness Model 8500 9100 9500HR Cross Trainers SECTION II DIAGNOSTIC MODES Life Fitness Model 8500 9100 9500HR Cross Trainers CT8500 CT9100 and CT9500HR Display Consoles The following three 3 Display Consoles are representative for each model crosstrainer The following Diagnostic State pages depict a CT9100 Display Console Regardless of Display Console the Message Center always provides current Diagnostic Data O HeartRate 0 Cal Hour CT9100 CT8500 Life Fitness Model 8500 9100 9500HR Cross Trainers ENTERING DIAGNOSTIC STATES 1 17 To enter the diagnostic mode proceed as follows 1 NOTE RPM diagnostic mode requires pedaling NOTE Factory defaults are displayed when the LED is illuminated on the ENTER key Press down and hold the DOWN ARROW key While doing this press the CLEAR CT9100 or CLEAR PAUSE CT9500 key twice within 2 5 seconds The console will go blank momentarily but do not release the DOWN ARROW key As soon as the MESSAGE CENTER displays t
11. BELT off the INTERMEDIATE PULLEY 3 Loosen the five 5 mounting bolts on the ALTERNATOR BRACKET and move the bracket upward and remove the DRIVE BELT off the crankshaft pulley assembly 4 Remove the CRANKSHAFT PULLEY ASSEMBLY by removing four 4 mounting bolts at the PILLOW BLOCK BEARINGS 5 Remove and discard the DRIVE BELT 6 Install new drive belt and alternator belt in reverse order Life Fitness Model 8500 9100 9500HR Cross Trainers How To Remove Power Control Board Assembly Tools Required Slotted head screwdriver and Phillips screwdriver 1 Remove the right REAR COVER See How To Remove Rear Covers 2 Disconnect the 12 and 11 Pin Connectors on the PCB 3 Remove the PCB from its mounting bracket 4 Install new PCB in reverse order Power Control Board Bracket Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Alternator Tools Required 3 8 Socket set and Standard wrench set and Phillips screwdriver Remove the REAR COVERS See How To Remove Rear Covers Disconnect the ALTERNATOR WIRING HARNESS from the alternator Remove the ALTERNATOR PIVOT BOLT and MOUNTING BOLT then lift out the alternator Install new alternator in reverse order Altemator Pivot Bol Altemator Mounting Bolt Torque Altemator Belt Nut Torque 50 60 ft lbs Altemator Pivot Bolt Altemator Belt New 85 ft lbs Used 60 ft lbs Main Drive Belt Inter
12. CONSOLE ASSEMBLY 4 Step 8 Place the CONSOLE ASSEMBLY SPACER 20 onto the CONSOLE SUPPORT ASSEMBLY 7 Align the mounting holes in the CONSOLE ASSEMBLY SPACER with those in the CONSOLE SUPPORT ASSEMBLY Step 9 Feed any excess WIRE HARNESS E down into the CONSOLE SUPPORT ASSEMBLY 7 Secure the CONSOLE ASSEMBLY 4 to the CONSOLE SUPPORT ASSEMBLY using four PHILLIPS PAN HEAD SCREWS 2 Tighten the screws securely CAUTION DO NOT OVER TIGHTEN THE PHILLIPS HEAD PAN SCREWS 2 CAUTION BE CAREFUL NOT TO PINCH THE WIRE HARNESS E WHEN ASSEMBLING THE CONSOLE ASSEMBLY 4 TO THE CONSOLE SUPPORT ASSEMBLY 7 8 Step 10 Locate the POLAR RECEIVER 16 Slide the FOAM ISOLATOR 15 over the POLAR RECEIVER Remove the POLAR RECEIVER JACK G locatedat the front of the MONOCOLUMN F near the PIVOT 5 SHAFT from the tape and plug the POLAR RECEIVER into the POLAR RECEIVER JACK Step 11 Locate the front and back MONOCOLUMN COVERS 5 amp 6 With the wire positioned on top carefully insert the POLAR RECEIVER 16 between the vertical ribs located inside the BACK MONOCOLUMN COVER 6 Place the BACK MONOCOLUMN COVER 6 over es the PIVOT SHAFT H at the top of the Model 9100 Shown gt MONOCOLUMN F NOTE THE POLAR RECEIVER WIRE MUST BE POSITIONED ON TOP WHEN INSERTED INTO THE REAR MONOCOLUMN COVER 6 Step 12 Model 9100 Only Place the FRONT MONOCOLUMN COVER 5 on the oppos
13. COVER 2 Then remove four 4 mounting bolts from the MONOCOLUMN COVERS and separate the two halves 3 Install new monocolumn covers in reverse order Monocolumn cs _Z Back Cover TS cV Monocolumn Models 8500 9100 Screws User Arm Cover Screws I UserAm NS Front Cove Ad n AM s 7 TAS IA R 5 Polar r 27 olar Receive Monocolumn H Polar Receiver Foam Front Cover aa UserAm Monocolumn Front Covers Rear Cover Monocolumn Screws Model 9500 20 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Frame Cover Tools required Phillips screwdriver Standard screwdriver Allen wrench set 3 8 Socket set and Wrenches 1 Remove the REAR COVERS See How To Remove Rear Covers 2 Remove the FRONT COVER 3 Remove the FRAME COVER which is adhered to the frame with double back tape 4 Install four 4 pieces of tape to the underside of the cover then install the FRAME COVER Front Cover Doubl back Adhesive Tape Four pieces 21 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Front Cover Tools required Phillips magnetic screwdriver 2 1 Remove the FRONT COVER screws 6 and separate the front cover halves 2 Install new front cover in reverse order Front ao Cover Screws PN Front Cover ron Screws 22 Life Fitness Model 8500 9100
14. ENTER key to advance to Diagnostic State 9 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 9 POWER SUPPLY Level Calories BATTERY Heart Rate Cal Hour Distance Watts Displa Aerobics Y Reverse Mode Mode W HEART RATE 10 20 30 40 50 60 70 80 90100 AGE Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH ira SLAA Press Quick Workout 2 ATTENTION CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL POLAN PERMA ARR TEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ aL aaga RR FAIBLE TOURDI OU COURT DE SOUFFLE n Life Fitness USA 1 800 735 3867 Life Fitness Inti 41 847 288 3300 There are two types of power supply sources BATTERY and EXTERNAL Make sure that the displayed value is BATTERY If need be change the value to BATTERY by pressing the UP ARROW key NOTE If external power is turned ON the 6 volt rechargeable battery will be drained Press the CLEAR key to return to Diagnostic State 8 Press the ENTER key to advance to Diagnostic State 10 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 10 SHUTDOWN TIME Level Calories Heart Rate Cal Hour Distance Watts RPM SHUTDOWN TIME 60 Yon oa
15. GK61 00002 0021 Nut 0017 00103 0025 GK61 00002 0023 Bolt Resistor Brac ket Assembly Stand Off 4 0017 00101 1606 GK61 00002 0024 0017 00042 0320 Keyway Altemator Cable Nut 4 0K53 01122 0000 61 00017 0000 0017 00103 0008 5 0017 00101 0333 Life Fitness Model 9500 Cross Trainers MODEL CT95 0100 17 SN 103198 Up PolarCable AK61 00014 0000 Main Cable AK61 00015 0000 Overlay Console Post Assembly AK61 00076 0001 Eng Met 61 00500 0010 Console Decal AK61 00075 0001 Eng Met HR Cable 0 61 01200 0000 61 00052 0002 Accessory GK61 00002 0018 Upper Am RT AK61 00048 00012 Front Post Cover Upper Arm LT 0K61 06350 0002 61 00048 0002 Rear Post Cover 0 61 06351 0002 Grips 2 v5 Pola rReceiver 0K61 05008 0000 F wt 0 p d 0K36 01059 0002 Install Ha rdware A AK61 00050 0000 5 Pedal Arm Covers RT Instruction Bag 2 0K61 06320 0001 Inside AK61 00049 0000 AK61 00018 0003 Outside 112 b cn cate Plug 2 0K61 06340 0002 E 3 Rear Boot Cover ORE 0 61 06341 0002 Rear Cover Lower Am Assembly 2 A Es AK61 00002 0016 GK61 00002 0019 my 4 Clevis Covers Assembly 2 2 6 205 AK 1 30062 0300 gt gt 1 Grommet MZ JE 0217 20042 0754 2 7 Front Cover RT Pedal Arm LT My 0K61 06250 0000 2 Front Cover LT GK61 00002 0005 Rear Cover 1 0 61 06240 0000 61 00002 0015 Pedal Arm Cov
16. LEVER to the ROCKER ARM and lower the 7 ES KES SSC CX pedal lever Es Ser n IR Pedal Lever p Remove the END CAP from the rocker arm A M 4 Remove bolt and washer slide off the rocker 2222 i e arm 2 Install new rocker in reverse order Units with split collar design make sure to position to within 005 gap of rocker arm Units with one piece collars make sure collar is positioned against shaft shoulder Torque 30 35 ftlbs Torque 30 35 ft lbs Flat Washer Flat Washer Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Tie Rod Tools required Phillips magnetic screwdriver 2 and 3 8 Socket set 1 Remove the OUTER LINK COVER by removing the six 6 mounting screws 2 Remove the TIE ROD NUT from the ARM EXTENSION and PEDAL ARM 3 Discard the tie rod and hardware 4 Install new TIE ROD in reverse order NOTE An identification mark on the tie rod must face towards the front of the machine Using a small amount of Moly grease between the inner race of the bearing and sleeve attach the tie rod at the rear of the machine first then at the front ied _ Cover Sc rews 6 Tue 6 10 IN LBS Outer Link Cover Spherical Washer Spherical Ca Linkage Nuts 2 End f 8901 18 20 FT LBS 3 Tum Thrust 2 0 Wave Washer Spring Flat Washer Rod Front end Front End Vie
17. PULLEY by loosening the five 5 bolts on the ALTERNATOR MOUNTING BRACKET Remove the INTERMEDIATE SHAFT BOLTand the INTERMEDIATE PULLEY Install new INTERMEDIATE PULLEY in reverse order Altemator Pivot Bolt Altemator Bracket Bolt Drive Belt Altemator Belt Altemator Mounting Bracket Altemator Pivot Bolt Torque 50 60 ft lbs Intermediate Shaft Bolt Altemator Belt New 85 ft lbs Used 60 ft lbs Main Drive Belt a dat New 170 ft lbs ntermeaiate Used 160 ft Ibs Pulley Altemator Bracket Torque 30 35 ft lbs Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Load Resistors Tools required Slotted screwdriver 1 Remove the right REAR COVER See How To Remove Rear Covers 2 Disconnect wires at the LOAD RESISTORS 3 Remove the LOAD RESISTORS by removing two 2 hex head screws securing the load resistor to the frame 4 Install new load resistors in reverse order Load Resistor Bracket and Screws Torque 33 37 in lbs Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The User Arms Tools required Allen wrench set and Phillips screwdriver 1 MODELS 8500 and 9100 Raise the BOOT COVERS on the UPPER ARMS MODEL 9500 Remove four 4 mounting bolts from the USER ARM REAR COVERS and remove these covers 2 Remove three 3 MOUNTING BOLTS from each UPPER ARM and lift off the user arm Units with Heart Rate
18. advance to Diagnostic State 2 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 2 INDIVIDUAL LED TEST AO aes Level Calories Heart Rate Cal Hour Distance Watts Displa gt lt HEART RATE 10 20 30 40 50 60 70 80 90100 AGE Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Quick Workout P ATTENTION CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL ress Quic card ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ Somnar a eo t FAIBLE TOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 In this test the system scrolls through each LED automatically to test its functionality Press the CLEAR key to return to Diagnostics State 1 Press the ENTER key to advance to Diagnostics State 3 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 3 Code Version and RPM Heart Rate and LDC Tests Level Calories HR Heart Rate Cal Hour Distance o Watts 0 222 Mode Mode HEART RATE GE Quick Start CAUTI ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT O
19. arms Adjust collars as necessary to take when pedal levers rotate under out the end play See How To load Replace Rocker Arms Pedal lever vibrates or squeaks during Align pedal lever See How To operation Replace Pedal Lever Pedal tape not adhering properly See How To Replace Pedal Lever Drive Belt slipping Loose or worn belt Check belt tension using a J10 belt gauge The belt deflection should be 1 4 7mm at 170 Ib for a new belt and 160 Ib for an existing belt Upper Arms feel loose Bolts that connect the upper and Adjust and tighten to a torque of 30 lower arms are loose 35 ft Ib Front to back play in pedal lever Worn bearings Check for front to back movement in bearings that connect pedal lever to the rocker arm Replace pedal lever assembly Poly V Pulley on intermediate shaft is Replace intermediate shaft loose assembly Crankarm loose Loosen setscrews and clamping screw in Crankarm Assembly Apply blue Loctite 242 on screws Tighten setscrews first and then tighten the clamping screw Worn link bearings Replace link Loose link mounting Clean lube and reassemble No Load Faulty cables power console board Enter diagnostic state 3 and execute or alternator the field duty cycle and increase the load If load does not increase replace alternator No LEDs on display Faulty display console Using a voltmeter verify 8Vdc at the 10 position Molex connector pin 1 on the display console PCB
20. bolt and nut at each ROCKER ARM joint and the hex bolt fom each ARM Cover Sc rews 6 EXTENSION ant it Anti Lift Bolts 2 Am Extensi Torque 5 Remove the PLUG from the LEFT Outer Link and RIGHT COVERS 6 Remove the REAR COVER by removing three 3 screws from the LEFT REAR COVER then seven 7 screws from the RIGHT REAR COVER 7 Install rear covers in reverse order Make sure that each pedal lever roller guide is centered over the roller If not lossen the pedal lever assembly mounting bolt and recenter the pedal lever so that it is centered on the roller then retighten the Pedal Lever Assembly b Pedal Lever Roller Guide mounting bolt Inconect Po END VIEW OF PEDAL LEVER Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Crankarm Roller Assembly and Cover Tools required Snap ring pliers and Allen wrench set and Phillips screwdriver 1 2 Remove the REAR COVERS See How Remove the ALLEN HEAD CAPSCREW from the end ot the ARM EXTENSION Remove the SNAP RING TAB WASHER and ROLLER BEARING ASSEMBLY on Old configuration assembly For New configuration assembly remove the setscrew and collar then remove the roller bearing assembly Remove the two 2 countersunk screws securing the crankarm cover to the crankarm and remove the CRANKARM COVER Install the CRANKARM COVER and ROLLER BEARING in the reverse order For new
21. 026 0001 Eng Met Decal Overlay 0K61 01200 0000 AK61 00025 0001 Eng Met Grips 2 Main Cable 0K61 06003 0000 61 00015 0000 Console Spacer 0 61 05009 0000 Upper Arm RT AK61 00460 0002 Upper Arm LT Boot 2 AK61 00460 0003 N SN 0 61 06000 0000 Grips 2 Front Post Cover 0 61 05008 0000 wwa 0 61 06010 0002 Rear Post Cover Install Ha rd ware 0 61 06020 0002 61 00040 0000 Instruction Bag Go uj lt gt 61 00042 0000 Pedal Am Covers RT Endcap 2 ae ane 0 61 06320 0000 Inside 0K61 06001 0001 A AK61 00019 0002 Outside A Lower Arm Assembly 2 Rear Cover RT GK61 00002 0022 GK61 00002 0014 EN Clevis Covers Assembly 2 i Plug 2 AK61 00062 0000 Grommet oe 0017 00042 0754 a gt Front Cover RT 0K61 06200 0000 2 Front Cover LT a o _ Rear Cover LT GK61 00002 0013 K Pedal Arm LT GK61 00002 0005 Wheel 2 GK61 00002 0011 Endcap 4 Cap Pedal Am Covers LT 0K61 06002 0001 0017 00012 1066 0K61 06300 0000 Inside AK61 00019 0000 Outside Leveler 4 0K61 01226 0002 2 Decal AK61 00035 0000 Life Fitness Model 8500 Cross Trainer MODEL CT85 0100 01 Tie Rod 2 G Am Extension 0K61 03004 0000 Bolt 0017 00101 1645 GK61 00002 0027 Drive Belt 0K61 02700 0000 Altemator w Flywheel AK61 00250 0001 Altemator 0017 00009 0841 Altemator Belt 0K53 01184 0000 Intermediate Pull
22. Cover ld 0 14 01384 0000 0K61 06341 0002 gt Rear Cover RT Lower Am Assembly 2 61 00002 0016 61 00002 0019 Clevis Covers Assemoly 2 AK61 00052 0320 Grommet 001 7 00042 0754 Front Cover RT Pedal Am LT 0K61 06250 0000 GK61 00002 0005 Front Cover LT 0K61 06240 0000 Rear Cover LT AK61 00002 0015 gt oO o Wheel 2 Endcap 4 GK61 00002 0011 Pedal Arm Covers LT 0K61 06002 0001 0K61 06300 0001 Inside AK61 00018 0001 Outside Decal Leveler 4 0K61 01222 00010 AK61 00035 0000 Life Fitness Model 9500 Cross Trainers MODEL CT95 0100 15 SN 100000 Up Arm Extension Tie Rod 2 0 61 03004 0000 GK61 00002 0020 E Bolt 0017 00101 1645 0017 00101 1646 Nut 0017 00103 0137 Sleeve 0K61 01076 0000 Pedal 2 Anti Lift Bracket 2 GK61 00002 0010 Tape 4 0K61 04114 0000 K61 04115 0002 Bolts 4 0K61 04115 000 0017 00101 1645 Roller 2 C 0K61 00002 0027 Drive Pulley Assembly Frame Cover 61 00230 0001 GK61 00002 0019 Drive Belt Pulley Tape 0K61 02700 0000 0K61 02409 0000 0K61 04115 0002 Magnet AK61 00044 0001 Pillow Bock Bearings 2 0K53 01181 0000 Battery 0017 00003 0685 27 14 0017 00042 0754 Crank Cove 0K61 03100 CODO Altemator w Flywheel AK61 00250 0001 Altemator 0017 00009 0841 Altemator Belt 0 53 01184 0000 Intermediate Pulley Assembly 61 00061 0000 CrankAm Assembly
23. E Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10 CT9100 8500 feature Use 4 and 6 KEYS to increment and decrement LDC value by 10 CT9500 feature Press the CLEAR key to return to Diagnostics State 2 Press the ENTER key to advance to Diagnostics State 4 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 3 Code Version and RPM Networking and LDC Tests DISPLAY LOCK EQUIPPED MODEL ONLY O Level Calories O Heart Rate O Cal Hour Distance Watts V HEART RATE 10 20 30 40 50 60 70 80 90100 Quick Start Press Start Press Quick Workout Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 Life Fitness UK 44 0 1353 666017 The items displayed for selection are Code Version RPM Networking and Load Duty Cycle LDC Code Version will be displayed under the TIME segment and will be a four 4 digit number Press the DISPLAY LOCK key or the 8 key CT9500 to access software part number go back to the original diagnostic screen press the DISPLAY LOCK key or the 8 key CT9500 To verify the RPM signal pedal and observe RPM value While pedaling press the ARROW keys to verify the alternator LOAD DUTY CYCLE Using the UP ARROW increase load resistance from 0 to 250 Zero 0 equals a no Load Duty Cycle LDC state 250 equals 100 of LDC The Loa
24. EDS AND KEYPAD 4 4 DIAGNOSTIC STATE 2 INDIVIDUAL LED 022441 5 DIAGNOSTIC STATE 3 CODE VERSION RPM HEART RATE LDC TESTS 6 DIAGNOSTIC STATE 3 CODE VERSION RPM NETWORKING LDC TESTS DISPLAY LOCK EQUIPPED MODEL 7 DIAGNOSTIC STATE 4 FIELD ALTERNATOR REGULATOR 8 DIAGNOSTIC STATE 5 PROGRAM VERSION AND NETWORKING TEST 9 DIAGNOSTIC STATE 5 LIFEPULSE TEST DISPLAY LOCK EQUIPPED MODEL 10 DIAGNOSTIC STATE 6 MAXIMUM WORKOUT 11 DIAGNOSTIC STATE 7 TELEMETRY 12 DIAGNOSTIC STATE 8 ENGLISH METRIC UNITS 13 DIAGNOSTIC STATE 9 POWER SUPPLY 14 DIAGNOSTIC STATE 10 SHUTDOWN TIME 15 DIAGNOSTIC STATE 11 PROGRAM TIME 16 DIAGNOSTIC STATE 12 17 DIAGNOSTIC STATE 13 METS ENABLE 18 DIAGNOSTIC STATE 14 KEYPAD 5 19 DIAGNOSTIC STATE 15 TOGGLE ENABLE
25. F BREATH Pa Press Quick Workout ATTENTION CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL s ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ FAIBLE ETOURDI OU A COURT DE SOUFFLE Fitness USA 1 800 735 3867 ier Fitness I ntl 1 847 288 3300 The items displayed for selection are Code Version RPM Heart Rate and Load Duty Cycle LDC Code Version will be displayed under the TIME segment and will be a four 4 digit number Press the DISPLAY LOCK key or the 8 key CT9500 to access software part number TO go back to the original diagnostic screen press the DISPLAY LOCK key or the 8 key CT9500 To verify the RPM signal pedal and observe RPM value To verify that the heart rate system is functioning properly use a polar simulator or a chest strap If the unit functions correctly the Heart Rate LED will illuminate and a heart rate value will be displayed in the MESSAGE CENTER under the LEVEL and CALORIES segment Otherwise if heart rate is not detected then the HR characters will be displayed and the HEART RATE LED will not be lit While pedaling press the ARROW keys to verify the alternator LOAD DUTY CYCLE Using the UP ARROW increase load resistance from 0 to 250 Zero 0 equals a no Load Duty Cycle LDC state 250 equals 100 of LDC The Load Duty Cycle value will be located under the HEART RATE and DISTANCE segment NOT
26. IDENTIFICATION MODEL IDENTIFICATION and SERIAL NUMBER 2 IN DI EET 3 SIN EET 5 OT 9500 Vows cic ent Suo raat deta aa OL INE UM II LUE MINUM DE 7 CT 9500 cest o Dus eau 9 NOTES ii sides E 11 SECTION VI MISCELLANEOUS INFORMATION PREVENTIVE MAINTENANCE 2 INSTALLATION 3 UNPACKING 9 COMMUNICATING BY 10 LE 455 it im 2000 Life Fitness a division of Brunswick Corporation All rights reserved Life Fitness Lifecycle and Lifepulse are registered trademarks and Heart Rate Zone Training and RELY ON IT are trademarks of Brunswick Corporation Polar is a registered trademark of Polar Electro Inc Any use of these trademarks without the express written consent of Life Fitness or the corresponding companies is forbidden 051 00 61 014 07 00 Life Fitness Model 8500 9100 9500HR Cross Trainers SECTION TROUBLESHOOTING GUIDES Life Fitness Model 8500 9100 9500HR Cross Trainers Malfunction Grinding rubbing knocking noises when pedal levers rotate under load Probable Cause Corrective Action Pulleys misaligned Loosen the pillow block bearings realign the pulleys and retighten the pillow block bearings Dirt build up in pedal tracks Cle
27. ING C warranty DATE CONTACT NAME CUSTOMER SUPPORT SERVICES ITEM NO PRODUCT TROUBLESHOOTING PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM TIME RECEIVED TIME COMPLETED TECHNICIAN NAME Section VI LEIEPTYnOSS CUSIOMER SUPPORT SERMC ES 10601 W Belmont Ave Frankin 60131 PHONE 800 351 3737 Toll Free or 708 451 0036 FAX 800 216 8893 Toll Free or 708 288 3702 Life Fitness Models 8500 9100 9500HR Cross Trainers NOTES
28. If voltage is present replace display console If not replace power control board Faulty power control board Using a voltmeter verify 8Vdc at 11 position connector pin 4 on the power control board If present replace console cable If not replace board Life Fitness Model 8500 9100 9500HR Cross Trainers Malfunction Probable Cause Corrective Action Alternator belt slipping Belt is loose Retension from 65 70 Ib No heart rate or erratic heart rate Pinched cable in Monocolumn cover Defective chest strap or improperly positioned Malfunctioning user arm Lifepulse CT9500HR Grip Assembly include worn or damaged heart rate lead Life Pulse user arm defective Loose or malfunctioning heart rate lead connection at Display Console Heart rate DSP Board CT9500HR is faulty or not communicating Malfunctioning Display Console Cross talk from telemetry and another transmitter or possible interference from other electronic devices Bad connection Remove monocolumn covers and inspect cables Replace damaged cable Replace chest strap or reposition it Reset transmitter Refer to Diagnostics state 3 to execute the heart rate test Verify heart rate cable is properly connected Using an ohmmeter verify continuity at the main console cable Replace user arm Lifepulse CT9500HR Assembly Verify user arm is functioning Wipe sensors dry Using an ohmmeter verify continui
29. LE ness Rely on it Models 8500 9100 and 9500HR Total Body Cross Trainers with Rear Drive System Customer Support Services SERVICE MANUAL Life Fitness Models 8500 9100 9500HR Cross Trainers INTRODUCTION HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES This service manual is applicable to Cross Trainer Models CT8500 CT9100 and CT9500HR 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 This manual is separated into six sections INTRODUCTION THEORY OF OPERATION TERMINOLOGY TABLE OF CONTENTS Section Q TROUBLESHOOTING GUIDES Section II Q DIAGNOSTIC TESTS Section III Q How To SERVICE AND REPAIR GUIDES Section IV ELECTRONICS OVERVIEW Q WIRING BLOCK DIAGRAMS Section V PARTS IDENTIFICATION Section MISCELLANEOUS INFORMATION Refer to TABLE OF CONTENTS for section topics When an operating problem occurs refer to troubleshooting guides and diagnostic tests in an attempt to isolate the cause When applicable guides and tests are listed by symptom followed with suggestions of probable cause s Once you have pinpointed the source of the problem refer to How To guides for recommended repair procedures How To sub sections are organized by replaceable part or assembly name For convenience sub section list
30. LLANEOUS INFORMATION gt c 9 o Life Fitness Model 8500 9100 9500HR Cross Trainers PREVENTIVE MAINTENANCE TIPS Preventive Maintenance Schedule Inside Outside Heatsink Connectors Board Main Drive Belt Oil Light Bearings Pedals Drive Pulley Clean Inspect Life Fitness Model 8500 9100 9500HR Cross Trainers INSTALLATION INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONS DO locate the Cross Trainer outdoors near swimming pools or in areas of high humidity DO NOT operate your Cross Trainer if it has been dropped damaged or even partially immersed in water Contact Life Fitness Customer Support Services at the number in the Operation Manual DO NOT locate the Cross Trainer any closer than 30 inches 76 cm to a television set DO NOT locate additional Cross Trainers any closer than a minimum of 42 inches 107 cm from center to center to avoid interference cross talk between Heart Rate monitors DO keep the area around your Cross Trainer clear of any obstructions including walls and furniture DO verify the contents of the delivery carton against the accompanying Parts Listing prior to setting the cartons and shipping material aside If any parts are missing contact Life Fitness Customer Support Services at the number listed in the Operation Manual Save the shipping cartons in case of return read the entire Operation Manual prior to attempting to oper
31. OSTIC STATE 17 PHOTOSHOOT DISPLAY LOCK EQUIPPED MODEL ONLY Heart Rate Cal Hour o Distance o Watts Calories 372 Time 28 45 52 HEART RATE 10 20 30 40 50 60 70 9 90100 AGE Quick Start Press Start Press Quick Workout Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 Life Fitness UK 44 0 1353 666017 Display values that have no significance and are used strictly for photographic sessions to assimilate values in the display console Press the CLEAR key to return to Diagnostic State 16 or continue to press the CLEAR key to exit diagnostics 24 Life Fitness Model 8500 9100 9500HR Cross Trainers NOTES 25 Life Fitness Model 8500 9100 9500HR Cross Trainers SECTION III How SERVICE AND REPAIR GUIDE Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace the Display Console Tools required Phillips screwdriver 1 Remove the MOUNTING SCREWS 4 from under the CONSOLE 2 Lift the console up enough to disconnect the 10 Pin and 3 or 4 Pin connectors Accessory Tray 3 Remove the console and spacer from the console Optional on CT85 only post or if equipped the accessory tray which is standard on CT95 91 and optional on 85 4 Install new console in reverse order 3 Pin Connector Console Spacer 10 Pin Connector YS 7 4 By Co
32. T APPAREIL s Cir fe D ARR TEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ Toons arcc ea At FAIBLE TOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 Display values that have no significance and are used strictly for photographic sessions to assimilate values in the display console Press the CLEAR key to return to Diagnostic State 15 or continue to press the CLEAR key to exit diagnostics 22 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 16 LANGUAGE CONFIGURATION DISPLAY LOCK EQUIPPED MODEL ONLY Heart Rate Cal Hour Distance Watts Level Calories HEART RATE 10 20 30 4 50 60 70 80 90100 Quick Start Press Start Press Quick Workout POLAR rampe Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 Life Fitness UK 44 0 1353 666017 This test allows the user to select a language for the unit Upon initial entry to this test a message concerning the current configuration of the language is displayed Following this message the user can change the language by pressing the arrow key to scroll through the available list of language in the product After the language has been selected pressing Clear or Enter keys will cause the product to save the language selected 23 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGN
33. VIS COVER into the bottom of the BACK CLEVIS COVER and pivot the FRONT CLEVIS COVER upward to fully meet the BACK CLEVIS COVER Secure the CLEVIS COVERS to the LEFT ROCKER ARM using two PHILLIPS PAN HEAD SCREWS 83 Tighten the screws securely PRE OPERATION CHECKLIST 1 Ensure that all fasteners are tight 1 Make sure the CROSS TRAINER is properly leveled and stable Refer to the Operation Manual 1 Ensure that the Leveler Jam Nuts are tight Refer to the Operation Manual 1 Read the entire Operation Manual before using the Cross Trainer Before attempting to operate your Cross Trainer it is imperative that you familiarize yourself with the contents of the Operation Manual If your Cross Trainer does not respond as described in the OPERATION MANUAL contact the nearest Life Fitness service center as listed in the Operation Manual Life Fitness Model 8500 9100 9500HR Cross Trainers UNPACKAGING INSTRUCTIONS Step 1 Remove all staples from the corrugated shipping container and fold down the four sides of the base tray A Step 2 Lift and open the top flaps of the shipping container sleeve B Lift and remove the two front support posts C Step 3 With the help of another person carefully lift the shipping container sleeve B up and off of the base tray A and over the Cross Trainer D Remove the ship kit box E from the Cross Trainer and set aside Remove the remaining corner posts F an
34. VOUS VOUS SENTEZ har St FAIBLE TOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 Maximum program duration can be adjusted from a range between 60 99 minutes Press the DOWN ARROW to decrease values in decrements of 1 minute Press the UP ARROW key to increase values in increments of 1 minute The LED on the ENTER key will illuminate when the value is set to the default of 60 minutes This value is stored in EEPROM and is stored when the cross trainer is not in use Press the CLEAR key to return to Diagnostics State 5 Press the ENTER key to advance to Diagnostics State 7 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 7 TELEMETRY ON OFF Level Heart Rate Cal Hour Time RPM Calories Distance Watts TELEMETRY ON eoe 595 Y HEART RATE Quick Start CAUTI ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout ON CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL Pa ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ b 22 49 FAIBLE TOURDI OU A COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 The default is TELEMETRY ON CT91 95 TELEMETRY OFF CT85
35. Z FAIBLE ETOURDI OU A COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 The PROGRAM TIME is the maximum time allowed for inputting weight age etc If no entry to program is made after the set program time from 60 99 seconds the unit automatically shuts off NOTE If no keys are pressed the unit will shut down after 15 seconds not 60 99 Pressing the CLEAR PAUSE key will return to Diagnostics State 10 Pressing the ENTER key will advance to Diagnostics State 12 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 12 STATISTICS Level O Heart Rate Cal Hour Time RPM Calories Distance Watts STATISTICS Displa 522 Mode HEART RATE GE Quick Start CAUTI ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout s ATTENTI ON CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL gt gt ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ FAIBLE TOURDI OU COURT SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 Press the UP ARROW to scroll forward through the programs for number of times each program has been selected Press the DOWN ARROW to scroll backwards through the programs to display total ho
36. an and remove dirt build up Rear roller wheels frozen Clean and lubricate with non detergent oil Link cover contacting rear cover Reposition rear cover s or replace Check that the inner link cover mounting screws are properly installed Excessive disk wobble Make sure no weld interference occurs between the crankarm and the disk cover Ensure that the crankshaft is flush with the crankarm and check for proper alignment See How To Faulty intermediate shaft assembly Replace intermediate shaft assy Faulty pillow block Replace pillow blocks on crankshaft Alternator Relieve tension on alternator spin flywheel for smoothness If thumping occurs faulty alternator Replace alternator Bearings at pivot points are out of Clean all sleeves in the linkage pivot position or dirty areas and lubricate with non detergent oil Setscrews or crankarm bolt in Loosen setscrew and clamping crankarm assembly are loose screw in crankarm assembly Apply blue Loctite 242 on screw threads Tighten setscrew first to set keyway then tighten clamping screw Crankarm bolt requires no Loctite Small extension arm bolt loose Replace small extension arm kit Faulty link bearings Replace link assembly Link mounting loose Clean lubricate and retighten Life Fitness Model 8500 9100 9500HR Cross Trainers Malfunction Probable Cause Corrective Action Grinding rubbing knocking noises Excessive end play in rocker
37. ate this machine as this is essential for proper use gt c o Life Fitness Model 8500 9100 9500HR Cross Trainers INSTALLATION INSTRUCTIONS TOOLS REQUIRED FOR ASSEMBLY Magnetic 2 Bit Phillips Screwdriver 5 16 amp 3 16 Hex Key Wrenches 1 2 Open End Wrench Hex Socket Head Cap Screw 3 8 16 x 1 0017 00101 1645 Phillips Pan Head Screw 8 18 x 3 4 0017 00101 1242 Front Monocolumn Cover 0 61 06020 0002 Model 9100 0 61 06350 0002 Model 9500HR Console Support Assembly AK61 00500 0004 Left Front Cover 0K61 06240 0000 Left User Arm Assembly Model 9100 Qty 14 Model 9500HR Qty 18 AK61 00460 0003 Model 9100 AK61 00048 0002 Model 9500HR Front Rocker Cover 0 61 06340 0002 Model 9500HR Only Foam Isolator Polar Receiver 0K36 01059 0002 Accessory Tray AK61 00045 0002 Acorn Nut 5 16 18 0017 00103 0287 Front Clevis Cover 0 61 06352 0002 Phillips Pan Head Screw 8 16 x 3 4 0017 00101 1148 Console Assembly AK61 00024 0001 Model 9100 AK61 00053 0001 Model 9500HR Back Monocolumn Cover 0 61 06010 0002 Model 9100 0 61 06351 0002 Model 9500HR Flat Washer 0017 00104 0192 Right Front Cover 0 61 06250 0000 Right User Arm Assembly AK61 00460 0002 Model 9100 AK61 00048 0001 Model 9500HR Back Rocker Cover 0 61 06341 0002 Model 9500HR Only Polar Receiver AK40 00045 0001 Button Head Cap Screw 5 16 18 x 5 8 0017 00101 1647 Cons
38. d Duty Cycle value will be located under the HEART RATE and DISTANCE segment The status of the LIFELINK board and LIFECENTER connection will be displayed in the CALORIES window The following message will be displayed NONE No LIFELINK board detected NULL Board detected but not communicating ON Online status with Life Center OFF Offline status with Life Center NOTE Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10 CT9100 8500 feature Press the CLEAR key to return to Diagnostics State 2 Press the ENTER key to advance to Diagnostics State 4 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 4 FIELD ALTERNATOR REGULATOR TEST Level Calories Heart Rate Cal Hour Distance Watts RPM FIELD ALTREG TST JOS WV HEART RAT Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout ATTENTION CONSULTEZ UN MEDECIN AVANT D UTILISER CET APPAREIL eae 2 ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ erry n FAIBLE ETOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 Prior to enter the test modes set the field load duty in diagnostics state 3 to 50 Press the Di
39. d ship kit support G IMPORTANT SAVE YOUR PACKING MATERIALS IN CASE OF Step 4 Using a screwdriver remove the rear locator pad H from the base tray A Step 5 Carefully lift the front of the unit and slowly roll the unit backward beyond the flattened base tray Step 6 Follow the Installation Instructions included in the parts bag to complete the assembly of your Cross Trainer Ship Kit Contents Y Left amp Right User Arms Y Console Support Assembly Y Left amp Right Front Covers Y Display Console Y Front amp Back Monocolumn Covers v Hardware Kit Y Installation Instructions Y Polar Receiver Kit 9100 9500HRR Only Y Reading Rack Assembly 9500HRR Only Y Heart Rate Monocolumn Covers 5500HR Only Y Line Cord International Only Y Power Supply Y Polar Transmitter Kit Section Life Fitness Model 8500 9100 9500HR Cross Trainers COMMUNICATING BY FAX If you would like to submit a parts order or if you need help troubleshooting a problem we have included for your convenience a FAX form on the following page Simply make a copy or copies of the FAX sheet and fill in the necessary information You may FAX us at any time 24 hours a day to either of the numbers shown A Life Fitness service representative will process your order or respond to your problem as quickly as possible 2727 L PARTS ORDER IF BOTH SALE PLEASE INDICATE 0 TROUBLESHOOT
40. ddition the 9500 model has Lifepulse contact HR The following is a description of each functional block CONSOLE The system voltage 6 7 5Vdc enters on connector P2 pin 1 and is used to power the LEDs and provide a supply voltage for the 5V regulator circuitry used to power the microprocessor section The Keypad entry user s input Lifepulse 9500HR only and Telemetry are all processed by the microprocessor The console outputs a PWM signal to the power control board to control the duty cycle of the load ALTERNATOR POWER CONTROL BOARD AND LOAD Using the PWM signal from the console the power control board switches the current on and off at the load via Q1 The control board also regulates the alternator voltage using the U1 comparitors Q3 and Q9 are used to sense the reed switch actuation autostart feature POLAR HR telemetry is implemented via a Polar receiver located in the rocker arm shroud at the front of the unit The Polar receiver connects to the console at connector P7 LIFEPULSE 9500 ONLY The handlebar electrodes connect to the console board at connector P9 Pins 1 and 4 are signal pins 2 and 3 are circuit reference Life Fitness Models 8500 9100 9500HR Cross Trainers TERMINOLOGY The following words and acronyms are commonly referred to throughout this manual Take time to familiarize yourself with them Connectors Electrical plugs used to connect wiring into electrical component Display Console El
41. disconnect electrical connector 3 Install new user arms in reverse order User Arm _ Cover Screws x W M Y User Am Lockwashers fr User Arm M j Hex Head Rear Covers User Arm Front Covers Model 9500 Model 9500HR Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Polar Receiver Tools required Phillips screwdriver 1 MODELS 8500 9100 Remove four 4 Monocolumn mounting bolts from the two halves of the Front Cover MONOCOLUMN COVER and separate 2 MODEL 9500 Remove four 4 mounting bolts from each USER ARM REAR COVER 2 Then remove four 4 mounting bolts from the MONOCOLUMN COVERS and separate the two halves 3 Locate the POLAR RECEIVER in the monocolumn and disconnect it from its Monocolumn jack Back Cover 4 Install a new POLAR RECEIVER in S RID SL Monocolumn reverse order D Scre Models 8500 9100 m User Arm ue lt 2 User Am 2 Front Covers 7 Monocolumn M E Polar Receiver Foam Front Cover Monocolumn Front Covers Rear Cover Monocolumn Screws Model 9500 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Monocolumn Cover Tools required Phillips screwdriver Monocolumn 1 MODELS 8500 9100 Remove four 4 Front Cover mounting bolts from the two halves of the MONOCOLUMN COVER and separate 2 MODEL 9500 Remove four 4 mounting bolts from each USER ARM REAR
42. e user and refreshes the status LEDs data display and profile display matrix Display EPROM ConnectorP7 Conn ctor Pl Connector P2 Connector and Pin Functions Connector Location unctional Description P1 is a 17 pin ribbon connector that connects to the Overlay Board P2 is a 10 pin connects to the VSYS POWER CONTROL 7 8VDC Alternator Control Board 10 VBAT 6VDC Life Fitness Model 8500 9100 9500HR Cross Trainers ELECTRONICS OVERVIEW DISPLAY CONSOLE BOARD Continued Connector Location Pin Functional Description P5 is an 8 pin connector that connects the Life Pulse Board to the Console Board Note Not applicable on CT9500 with Display Lock feature P7 is a 3 pin connector that comes from the Polar connector 1 1 HRENABLE 38VDO 0 000 e 3 VSYS 7 8VDC 202 4 vsyS 7 8VDC 2 0 5 GROUND 2 0 6 GROUND 7 HRDO 47VDO 0 0 000 8 HRDI 47VDO 02 4VCC 5VDC 2 SIGNAL Section IV Life Fitness Model 8500 9100 9500HR Cross Trainers ELECTRONICS OVERVIEW POWER CONTROL BOARD Functional Description The Power Control Board is designed to regulate the alternator voltage by modulating the field current It regulates the pass current RPM signal from the Alternator to the Console and the pass current from the alternator to the load resistor while providing supply voltage for the console ConnectorP2
43. ectronic board for making settings and monitoring physical output Board uma LONMLTICDDD NNNM LL INN Revolutions per minute describes the amount of times something turns within a minute of time Life Fitness Models 8500 9100 9500HR Cross Trainers TABLE OF CONTENTS SECTION TROUBLESHOOTING GUIDES PAGE GRINDING RUBBING KNOCKING 2 DRIVE BELT SLIPPING i iic oii ti i rh Cod RR ER E PEDE AE nd shes 3 UPPER ARMS LOOSE tee et ee teet e ete d tu alte 3 PEAY IN PEDAL LEVER cc eret etr eod des teer eter ete e ee Rae 3 EP MEM 3 NO LEDS ON DISPLAY irei pirani etie nein tenth 3 ALTERNATOR BELT SLIPPINQ 2 err tnter ern nete een nen es 4 NO HEART RATE OR ERRATIC HEART RATE nnne 4 NO LEDS or RANDOM LEDS Li ierra dnia i inh tot ttt ten he he RE ISRAEL 5 earl MM 5 AUTO START FAILURE de ene tenete buta Ste edis ee EHE ER tu d Eta tas 5 NOTES ih qu barra toe Doct end da boe dies abd eda abe 6 SECTION II DIAGNOSTIC MODES DISPEAY GONSOLEEBS yet ott dh 2 ENTERING DIAGNOSTIC STATES 1 17 emere nennen 3 DIAGNOSTIC STATE 1 L
44. ed Apply four 4 pieces of double back adhesive tape the pedal arm assembly as shown Reinstall the pedal and apply 30 40 psi clamp pressure for approximately 60 seconds or longer Pedal Am Assembly on Double back Adhesive Tape 4 pieces EN Life Fitness Model 8500 9100 9500HR Cross Trainers How To Set Jumpers on CSAFE Card Tools required Phillips screwdriver Front Cover 1 Remove six 6 screws from the FRONT COVER and separate the front cover halves Frame Bottom 2 Set jumpers according to chart below 3 Reinstall FRONT COVERS JUMPER SETTINGS CSAFE Card OUT OUT OUT IN Mounting Bracket Front Cover REMOVE this jumper JW1 for Rear Drive Cross trainers DM 429444 IE 27 Life Fitness Model 8500 9100 9500HR Cross Trainers NOTES 28 Life Fitness Model 8500 9100 9500HR Cross Trainers SECTION IV ELECTRONICS OVERVIEW AND WIRING BLOCK DIAGRAMS o Life Fitness Model 8500 9100 9500HR Cross Trainers ELECTRONICS OVERVIEW DISPLAY CONSOLE BOARD Functional Description Connector P5 Not applicable on 9500 with Display Lock only The Display Console Board is designed to work in conjunction with the Alternator Control Board It reads the keypad input for changes or updates by th
45. ers LT ec 0K61 06300 0001Inside Endcap 4 eel 2 AK61 00018 00010utside 0K61 06002 0001 GK61 00002 0011 Decal 0K61 01222 0001 2 Leveler 4 AK61 00035 0000 gt Oo o Life Fitness Model 9500 Cross Trainers MODEL CT95 0100 17 SN 103198 Up Tie Rod 2 GK61 00002 0020 Amm Extension 0017 00101 1646 0K61 03004 0000 Nut Bolt 0017 00103 0137 Sleeve 0K61 01076 0000 0017 00101 1645 Pedal 2 GK61 00002 0010 Tape 4 a 0K61 04115 0002 0 61 04114 0000 Bolts 4 0017 00101 1645 Roller Kit GK61 00002 0027 Drive Pulley Assembly Drive 0 61 02409 0000 0K61 02700 0000 1 04115 0002 61 00044 0001 7 Battery Altemator w Flywheel Pillow Block Bearings 2 0017 00003 0685 AK61 00250 0001 0 53 01181 0000 Altemator 0017 00009 0841 Altemator Belt 0 53 01184 0000 Intermediate Pulley Assembly AK61 00061 0000 14 0017 00042 0754 Crark Cover 0 61 C310 29000 Crank Am Assembly GK61 00002 0021 Nut 0017 00103 0025 Bolt GK61 00002 0023 0017 00101 1606 Stand Off 4 Ke GK61 00002 0024 yway Altemator Cable T Screw 61 00017 0000 0017 00103 0008 24 Resistor Bracket Assembly Life Fitness Models 8500 9100 9500HR Cross Trainers NOTES gt c 2 o Life Fitness Model 8500 9100 9500HR Cross Trainers SECTION VI MISCE
46. ey Assembly AK61 00061 0000 fF Resistor Bracket Assembly GK61 00002 0024 Altemator Cable AK61 00017 0000 SN 100000 Up K61 00002 0020 Bolt 0017 00101 1646 Nut 0017 00103 0137 Sleeve 0K61 01076 0000 Pedal 2 GK61 00002 0010 Tape 4 0K61 04115 0002 Anit Lift Bracket 2 0K61 04114 0000 Bolts 4 0017 00101 1645 Drive Pulley Assembly AK61 00230 0001 Frame Cover Pulley GK61 00002 0003 0K61 02409 0000 Tape Magnet 0K61 04115 0002 AK61 00044 0001 Battery 0017 00003 0685 Pillow Bock Bearings 2 0K53 01181 0000 Se gt 4 SD LOL Grommet 14 X es 0017 00042 0754 gS OA Cran Cover se 0X61 031 0 020 Crank Am Assembly GK61 00002 0021 Nut 0017 00103 0025 Bolt PCB 0017 00101 1606 GK61 00002 0023 Keyway Stand Off 4 0K53 01122 0000 0017 00042 0320 Allen Screw Nut 4 0017 00101 0333 0017 00103 0008 Life Fitness Model 9100 Cross Trainer MODEL CT91 0100 01 Console AK61 00024 0001 Eng Met Overlay AK61 00023 0001 Eng Met Main Cable AK61 00015 0000 Polar Cable AK61 00014 0000 Console Spacer 0 61 05009 0000 Accessory Tray GK61 00002 0002 Upper Arm LT AK61 00460 0003 Grips 2 0K61 05008 0000 Install Hardware AK61 00040 0000 Instruction Bag AK61 00043 0000 Endcap 2 0 61 06001 0001 Lower Arm Assembly 2 GK61 00002 0022 Clevis Covers Assembly 2 AK61 00062 0000 Grommet 0017 00042 0754 Fr
47. he word DIAGNOSTICS then release the DOWN ARROW key Press the ENTER key to scroll through diagnostic states 1 17 Press the UP and DOWN ARROW keys to activate a selection within a diagnostic state Press the CLEAR key to scroll back to a previous diagnostic state Press the CLEAR key as required to exit out of the diagnostic program For diagnostic states that have a subdirectory press the DISPLAY LOCK key to enter Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 1 LEDs and KEYPAD TEST Level Heart Rate Cal Hour Time Calories Distance Watts Message Center V HEART RATE M GE EN ET F Quick Star CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Pn Press Quick Workout ATTENTION CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL ARRETEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENT PELAR FAIBLE TOURDI OU A COUR ede Life Fi ife Fi Profile Window Initially all LEDs are lit When pressing the keys listed below the appropriate character should display across the MESSAGE CENTER CROSSTRAINER 950 KEY MODE DEPRESSED Display Lock Clear Pause Aerobics Mode Reverse Mode Quick Workout Up Arrow Down Arrow Start m SS Press the CLEAR key to exit diagnostic mode Press the ENTER key to
48. ite side of the BACK MONOCOLUMN COVER 6 to cover the PIVOT SHAFT and CONSOLE SUPPORT ASSEMBLY MOUNTING SCREWS Use four PHILLIPS PAN HEAD SCREWS 3 to secure the MONOCOLUMN COVERS together Tighten the screws securely Step 13 Model 9500HR Only Place the FRONT MONOCOLUMN COVER 5 on the opposite side of the BACK MONOCOLUMN COVER 6 to cover the PIVOT SHAFT and CONSOLE SUPPORT ASSEMBLY MOUNTING SCREWS Interlock the top tabs and use two PHILLIPS PAN HEAD SCREWS 3 to secure the bottoms of MONOCOLUMN COVERS together Tighten the screws securely CAUTION DO NOT OVER TIGHTEN THE PHILLIPS PAN HEAD SCREWS 3 Step 14 Model 9500HR Only Locate one FRONT ROCKER COVER 13 and one BACK ROCKER COVER 14 Position the FRONT ROCKER COVER over the user side of the left end of the PIVOT SHAFT F as shown making sure that it interlocks with the MONOCOLUMN COVERS 5 amp 6 Place the BACK ROCKER COVER over the opposite side of the left end of the PIVOT SHAFT in the same manner Secure the covers using three PHILLIPS PAN HEAD SCREWS 3 Repeat the procedure reversing front and back for the user right end of the pivot shaft gt o Model 9500HR Shown Step 15 Rotate the LEFT ROCKER ARM B to its fullest rear position Locate one FRONT CLEVIS COVER 21 and one BACK CLEVIS COVER 22 Position the BACK CLEVIS COVER at the LEFT CLEVIS JOINT J Hook the bottom tabs of the FRONT CLE
49. ler bearing assemblies make sure that a maximum of 005 clearance is maintained between the ROLLER BEARING and the COLLAR Crank Cover Torque 30 35 ft lbs Pa RollerBearing pts Assembly A Snap Am Extension 7 4 Ring Tab Washer Allen head Cap screw N Torque 30 35 ft lbs NA s Screws 2 Torque 65 75 in lbs Old Style Crankam Poller Assembly Cover MUST Tum Freely Roller Bearing Assembly After Assembly 005 MAX Clearance Am Extension Am Extension Torque 28 33 in lbs 2 places Collar NEW STYLE Crankam Cover Crankam Nut Crankarm Assembly Crankarm Bolt Crankam Key Setsc rew BACKSIDE VIEW Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Drive Belt and Alternator Belt Tools required 3 8 Socket set and Standard wrench set and Phillips screwdriver Altemator Belt New 75 85 lbs Main Drive Belt New 170 lbs Used 160 lbs Crankshaft Pulley Assembly Pivot Bolt Torque 50 60 ft lbs Mounting Bolt Torque 18 20 ft lbs Pillow Bock Bearing Nuts Altemator Torque Support Bracket 30 35 ft lbs Intermediate 5 Torque Pulley 30 35 ft lbs 1 Remove the both REAR COVERS See How To Remove Rear Covers 2 Loosen the ALTERNATOR PIVOT BOLT and release tension on the alternator belt then remove the ALTERNATOR
50. mediate New 170 ft lbs Pulley Used 160 ft Ibs Mounting Bolt Torque 18 20 ft lbs Life Fitness Models 8500 9100 9500HR Cross Trainers How To Replace Alternator Belt Tools Required 3 8 Socket set and Standard wrench set and Phillips screwdriver 1 Remove the REAR COVERS See How To Remove Rear Covers Altemator Mounting 2 Loosen the ALTERNATOR PIVOT Bolt BOLT and its MOUNTING BOLT Altemator Pivot Bolt 3 Rotate the alternator down to release belt tension then remove the ALTERNATOR BELT 4 Install new alternator belt in reverse order Altemator Belt New 85 ft Ibs Used 60 165 Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Pedal Lever Assembly Tools required Phillip screwdriver Allen wrench set 3 8 Socket set and Standard wrench set i Remove six 6 screws from the OUTER LINK COVER and remove cover Remove the TIE ROD Remove the CLEVIS COVER from each pedal lever Remove the ANTI LIFT BRACKET and lower the PEDAL LEVER ASSEMBLY Remove the nut and bolt securing the pedal lever to the ROCKER ARM and remove the pedal lever Remove the inner link cover screws 4 and remove the inner link cover Install new pedal lever in reverse order except as follow A When tightening the clevis to the pedal lever bolt the pedal lever track must be Pedal Lever Nuts 2 Torque 30 35 FT LBS Rear Cover RH Cover Screws 6
51. nnector Z 9500 only 2 D A Console Support Assembly Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace the Accessory Tray Optional on CT8500 Tools required Phillips screwdriver Allen wrench set and 3 8 Standard wrench set 1 Remove the MOUNTING SCREWS 4 from under the CONSOLE Accessory Tray 2 Lift the console up enough to disconnect 3 Pin SEN the 10 Pin 3 Pin or 4 Pin connectors Connector Console 10 Pin Xx 3 Remove the console and spacer from the Connector ie Spacer accessory tray m xL LN Accessory 4 Remove the ACCESSORY TRAY Tray Screws 4 BOLTS 4 and NUTS 4 and lift off the ACCESSORY TRAY from the console Accessory 4 Pin post Tray Nuts 4 4 Connector oA 9500 only 5 Install new accessory tray in reverse order Display wd NL Console 4 Screws 4 zo pz Support Assembly Life Fitness Models 8500 9100 9500HR Cross Trainers How To Replace the Display Console Support Assembly Tools required Phillips screwdriver and Allen wrench set Rocker Cover and Screws 3 Polar Receiver yi Back J Rocker de Polar Gover RAN Receiver Foam Insulator Monocolumn oe E x Cx Cae over 3p Monocolumn Foam Insulator Monocolumn P s Cover N Monocolumn r 4 a pis gt aa Cover Screws 2 94 Sh Ne 55 Front Rocker Model 8500 9100 Shown M
52. ole Spacer 0 61 05009 0000 Back Clevis Cover Qty 2 06353 0002 1 Before proceeding familiarize yourself with the parts of the Cross Trainer and make sure that you have received all the items described in the Parts List Step 2 Locate the left and right FRONT COVER 9 10 Using two PHILLIPS PAN HEAD SCREWS 3 mount 3 the USER LEFT FRONT COVER 9 to the FRAME A Attach the USER RIGHT FRONT COVER 10 to the FRAME in the same manner using two PHILLIPS PAN HEAD SCREWS 3 Secure the tops of the FRONT COVERS together using two PHILLIPS PAN HEAD SCREWS 3 Step 3 Model 9100 Only Locate the LEFT USER ARM 11 Secure the LEFT USER ARM to the LEFT ROCKER ARM B using three HEX SOCKET HEAD CAP SCREWS 1 Repeat the procedure for the RIGHT USER ARM 12 and RIGHT ROCKER ARM C Tighten all screws securely Slide the BOOT COVERS D located on the user arms down over the mounting plates Model 9500HR Only Locate the LEFT USER ARM 11 Snap the 2 PIN CONNECTOR 2PA located at the bottom of the LEFT USER ARM into the 2 PIN CONNECTOR 2PB positioned at the top of the LEFT ROCKER ARM B Feed the connectors and excess cable up into the LEFT USER ARM Secure the LEFT USER ARM to the LEFT ROCKER ARM using three HEX SOCKET HEAD CAP SCREWS 1 and INTERNAL LOCK WASHERS 23 Repeat the procedure for the RIGHT USER ARM 12 and RIGHT ROCKER ARM C Tighten all screws secu
53. onocolumn Model 9500HR Shown Jw Gover Cover Screws 4 Front Rocker Cover and Screws 3 1 Remove the console and accessory tray See How To 2 Remove the MONOCOLUMN COVER ALL lt MODELS and ROCKER ARM COVERS 9500 3 Pin Accessory TAN Connector Tray n Console 3 Remove the POLAR RECEIVER des Fin x 4 Remove the two 2 HEX HEAD CAPSCREWS ang ector FLAT WASHERS securing the CONSOLE Eze SUPPORT ASSEMBLY Tray Screws 4 Tray Nuts 4 5 Lift the CONSOLE POST out of the MONOCOLUMN while guiding the wire harness out 4 Connector 9500 6 Install new console support in reverse order Display Console Screws 4 Console Support Hex Assembly Bolts 2 9 9 Veces i i Flat Washers 2 Wire Harness Monocolumn Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Rear Covers Tools required Phillips magnetic screwdriver 2 Allen wrench set 3 8 Socket set and Standard wrench set 1 Remove the OUTER LINK COVER by removing six 6 mounting screws from each OUTER LINK COVER RearCoverRH Pedal Lever Nuts 2 Torque 30 35 FT LES 2 Remove the ANTI LIFT BRACKET by removing two 2 mounting bolts from each bracket Rear Cover LH Clevis Covers 3 Remove the clevis cover from each pedal lever J oa ER 4 Remove the PEDAL LEVER removing the mounting
54. ont Cover RT 0K61 06250 0000 Pedal Amm LT Front Cover LT K61 3 0K61 06240 0000 2 09902 09005 Pedal Am Covers 0 0 61 06300 0001 Inside AK61 00056 0002 Outside Decal 0 61 01230 0001 2 SN 100000 Up Console Post Assembly 61 00500 0004 Decal 0 61 01200 0000 Grips 2 Pedal Arm RT 61 00002 0006 0 61 06003 0000 Upper Arm RT AK61 00460 0002 Boot 2 0K61 06000 0000 Front Post Cover 0K61 06010 0002 Rear Post Cover 0K61 06020 0002 PolarReceiver SK40 00045 0001 Foam Isolator 0K36 01059 0002 Pedal Arm Covers RT 0K61 06320 0001 Inside AK61 00056 0001 Outside Endcap 4 0K61 06002 0001 p LA Z th Rear Cover LT AK61 00002 0015 Wheel 2 _ Rear Cover RT yp OX 61 00002 0016 Plug 2 2277 T OK14 01384 0000 SE J 1 GK61 00002 0011 Leveler 4 AK61 00035 0000 gt Oo o Life Fitness Model 9100 Cross Trainer MODEL CT91 0100 01 Tie Rod 2 GK61 00002 0020 Am Extension 0K61 03004 0000 Bolt 0017 00101 1645 Bolts 4 Roller Kit GK61 00002 0027 Drive Pulley Assembly AK61 00230 0001 Drive Belt Pulley 0K61 02700 0000 0K61 02409 0000 Magnet AK61 00044 0001 Altemator w Flywheel AK61 00250 0001 Altemator 0017 00009 0841 0K53 01181 0000 Altemator Belt 8 0K53 01184 0000 Intermediate AN 3 E ix Pulley Assembly Pit h c AK61 00061 0000 NM
55. rely CAUTION BE CAREFUL NOT TO PINCH THE WIRE HARNESSES WHEN ASSEMBLING THE USER ARMS 11 amp 12 TO THE ROCKER ARMS B amp C Model 9500HR Only gt Model 9500HR Shown 9 Step 4 Detach and unwrap the WIRE HARNESS 4P 9500HR Only located at the top of the MONOCOLUMN F Holding the CONSOLE SUPPORT ASSEMBLY 7 with the handgrips facing upward feed the WIRE HARNESS up through the neck and out the top access hole Carefully lower the CONSOLE SUPPORT ASSEMBLY into the MONOCOLUMN CAUTION BE CAREFUL NOT TO PINCH THE WIRE HARNESS E WHEN ASSEMBLING THE CONSOLE SUPPORT ASSEMBLY 7 TO THE MONOCOLUMN F Step 5 Using two HEX SOCKET HEAD CAP SCREWS 1 and two FLAT WASHERS 8 secure the CONSOLE SUPPORT ASSEMBLY 7 to the MONOCOLUMN F Tighten the screws securely Step 6 Locate the ACCESSORY TRAY 17 Feed the WIRE HARNESS E through the center access hole Place the ACCESSORY TRAY on the CONSOLE SUPPORT ASSEMBLY 7 as shown Using four BUTTON HEAD CAP SCREWS 18 and ACORN NUTS 19 secure the ACCESSORY TRAY to the CONSOLE SUPPORT ASSEMBLY through the large mounting holes Tighten the screws securely Step 7 Model 9500HR Shown Attach the 3 PIN 3P and 10 PIN 10P CONNECTORS to the corresponding jacks on the back of the CONSOLE ASSEMBLY 4 Model 9500HR Only Attach the 4 PIN 4P CONNECTOR to the corresponding jack on the back of the
56. resting on the roller on the crankarm See illustrastion below B The identificaion mark on the tie rod must be forward C An identification mark on the tie rod must face towards the front of the machine Using a small amount of Moly grease between the inner race of the bearing and sleeve attach the tie rod at the rear of the machine first then at the front D Use a small amount of grease between the spherical washer and the spherical end sleeve Pedal Lever Assembly Pedal Lever Roller Guide Crankam Shaft NO Incorrect Position the Roler Roller Corect Postion ofthe Roller END MEW OF PEDALLEVER Tongue 6 10 IN LBS Anti Lift Bolts 2 Torque Outer Link 30 35 FT LBS Cover Spherical Washer e ies Linkage Nuts 2 Sleeve i 18 20 FT LBS 3 Tum Thrust ai Y Wave Washer J Spring Te Rod Front end Front End View CB Sleeve 0 Thrust 3 Tum 7 Wave Washer Spring Flat Washer BackEnd View Life Fitness Models 8500 9100 9500HR Cross Trainers How To Replace Rocker Arms Tools required 3 8 Socket set and Standard wrench set 1 Remove the UPPER ARMS See How pil To Replace User Arms S End Cap Remove the MONOCOLUMN COVERS and Torque CLEVIS COVERS 30 35 FT IBS EolsQ Remove the clevis cover from each pedal lever ON 7 SS iN Remove the nut and bolt securing the PEDAL E ba X
57. s recommended Tools Required to complete each specific function Refer to the PARTS IDENTIFICATION section to identify proper name and number of part to order for repair of equipment A 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 7 00 PM C S T To speed Life Fitness Customer Support Services response to your needs please be prepared to provide the following information to the phone technician 1 Model number 2 Serial number consists of 3 letters and 6 numbers 3 Symptom of problem 4 Part name and number to order if known Before installing a part review How To and follow the step by step procedures recommended to install the part safely and efficiently 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 847 451 0036 or Toll Free 800 351 3737 FAX 847 288 3702 or Toll Free 800 216 8893 Life Fitness Models 8500 9100 9500HR Cross Trainers THEORY OF OPERATION The electronic system on the rear drive crosstrainer is made up of three main functional blocks 1 Console 2 HR telemetry and 3 Alternator Power Control Board and Load In a
58. splay Lock key or the number 2 key for CT9500 only once to access Field Test Use the UP DOWN ARROW toggle the field voltage ON and OFF This will verify the operation of the alternator and cable connections The resistance should increase as the field test is turned on Press the Display Lock key or the number 2 key for CT9500 only again to access the Alternator Regulator Test Use the UP DOWN ARROW key to toggle voltage ON OFF This will verify that the power control board is regulating the voltage properly and the load resistance should slightly decrease as the alternator regulator is turned on Press the CLEAR key to return to Diagnostics State 3 Press the ENTER key to advance to Diagnostics State 5 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 5 PROGRAM VERSION AND NETWORKING TEST Level O Calories Heart Rate Cal Hour O Distance Watts NONE RPM P XXX Time P XXX 329 222 HEART RATE 10 20 30 40 50 60 70 80 90 100 AGE Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout oe EM ATTENTI ON CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL POLAN Q ELEREN EA ARR TEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ mv M m FAIBLE ETOURDI OU A COURT DE SOUFFLE d
59. style roller bearing assemblies make sure that a maximum of 005 clearance is maintained between the ROLLER BEARING and the COLLAR Crank Cover Collar Torque 30 35 ftlbs Arm Extension Remove Rear Covers Crankam Cover PE Roller Bearing EN Assembly gt N Snap Am Ring Extension Allen head Cap screw Torque 30 35 ft lbs lt Screws 2 B Torque 65 75 in lbs Old Style Crankam Poller Assembly Cover MUST Tum Freel Roller Bearing Assembly j 005 Clearance g Torque 28 33 lbs 2 places NEW STYLE Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Crankarm Assembly Tools required Snap ring pliers and Allen wrench set and Phillips screwdriver 1s Remove the REAR COVERS See How To Remove Rear Covers Remove the ALLEN HEAD CAPSCREW from the end ot the ARM EXTENSION Remove the SNAP RING TAB WASHER and ROLLER BEARING ASSEMBLY on Old configuration assembly For New configuration assembly remove the SETSCREW and COLLAR then remove the roller bearing assembly Remove the two 2 countersunk screws securing the crankarm cover to the crankarm and remove the CRANKARM COVER Remove the NUT and BOLT from the CRANKARM Remove the SETSCREW and KEY from the CRANKARM Remove the CRANKARM off the shaft Collar Install the CRANKARM COVER and ROLLER BEARING in the reverse order For new style rol
60. the cross trainer is not in use Press the CLEAR key to return to Diagnostic State 12 Press the ENTER key to advance to Diagnostic State 14 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 14 KEYPAD SELECTION Level Calories 79155 K PAD ON O Heart Rate Cal Hour Distance Watts OO HEART RATE GE Quick Start CAUTI ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout err ATTENTI ON CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL e FISELA 4 ee eee ARRETEZVOUS 51 VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ FAIBLE TOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness Intl 1 847 288 3300 To select the appropriate keypad press the UP DOWN ARROW keys for the designated model Make sure that the system displays CT9500 K PAD CT91 55 K PAD or CT8500 K PAD depending machine model Press the CLEAR key to return to Diagnostic State 13 Press the ENTER key to advance to Diagnostic State 15 20 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 15 TOGGLE ENABLE DISABLE Level Calories TOGGLED DISABLED Heart Rate Cal Hour Distance Watts RPM
61. the user has placed their hands on the lifepulse sensors When the left sensor detects hands on condition a L will be placed in the profile window with the heart When the right sensor detects hands on condition a R will be placed in the profile window with the heart A timer will start counting from the time when a both left and right hands on condition occurs to when the lifepulse system can reliable give the user their heart rate This timer will stop when the heart rate is given The gain value of the heart rate signal is shown The confidence level of the heart rate value is displayed The value ranges from 0 to 9 A value of 9 is considered to be high confidence A value of 0 is considered to be low confidence Press the CLEAR key to return to Diagnostics State 4 Press the ENTER key to advance to Diagnostics State 6 Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 6 MAXIMUM WORKOUT DURATION Level Heart Rate Cal Hour Time RPM Calories Distance Watts MAX DURATION 60 eoo ENS HEART RATE 10 20 30 40 50 60 70 80 90100 AGE Quick Start CAUTION CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH i Press Quick Workout pru P ATTENTI ON CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL nr ARR TEZVOUS SI VOUS AVEZ DES DOULEURS SI
62. ty between Lifepulse sensor and cable connection Replace if defective Secure connection Replace malfunctioning user arm Lifepulse CT9500HR Grip Assembly Verify that the heart rate DSP board CT9500HR is communi cating defective replace Test with known good Display Console Replace malfunctioning Display Console Position Cross Trainer at least 3 ft 1 m from unit with telemetry or from other electronic devices Check for corrosion on connectors Disconnect and reconnect telemetry receiver Life Fitness Model 8500 9100 9500HR Cross Trainers Malfunction Probable Cause Corrective Action No LEDs or random LEDs lit Cable connection faulty Remove display console and verify cable is properly plugged into console Main wire harness damaged Check for a damaged wire harness Replace wire harness No RPM Unit shuts off one minute Bad cable connection Verify cables connections at console into program to power control PCB and power control PCB to alternator Disconnect and reconnect cables Using a voltmeter verify cable continuity on console to power control PCB and power control PCB to alternator Auto start failure Operator must be pedling unit for the auto start feature to activate Battery Battery voltage should be 5 8 6 3 Vdc If not replace the battery Bad cable connection Verify cables connections at console board and reed switch are correct and connected properly
63. urs Press the CLEAR key to return to Diagnostic State 11 Press the ENTER key to advance to Diagnostic State 13 STATISTICS HOURS Number of hours FA Number of times umber of times FAT umber of times umber of times umber of times Number of times HR WIPE Number of times wiping of hand sensor message Number of times umber of times Life Fitness Model 8500 9100 9500HR Cross Trainers DIAGNOSTIC STATE 13 METS ENABLE DISABLE Level Calories METS OFF Heart Rate Cal Hour Distance o Watts 208 HEART RATE GE Quick Start CAUTI ON CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT Press Start STOP EXERCISING IF YOU FEEL PAIN FAINT DIZZY OR SHORT OF BREATH Press Quick Workout rp i ATTENTI ON CONSULTEZ UN M DECIN AVANT D UTILISER CET APPAREIL 4 r ARR TEZVOUS SI VOUS AVEZ DES DOULEURS SI VOUS VOUS SENTEZ FAIBLE ETOURDI OU COURT DE SOUFFLE Life Fitness USA 1 800 735 3867 Life Fitness I ntl 1 847 288 3300 Press the DOWN ARROW to disable the METS mode Press the UP ARROW to enable the METS mode METS is the expression of the rate of work power output One MET is approximately equal to a person s metabolism when seated and relaxed When the value is set to METS OFF default the ENTER key LED will illuminate This value is stored in EEPROM and is stored when
64. w Tie Rod Back end Shoulder Linkage Nuts 2 Sleeve lt L Torque 18 20 FT LBS Thust Wave Washer Spring Flat Washer BackEnd View Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace Crankshaft Pulley Assembly Tools required Allen wrench set 3 8 Socket set and Standard wrench set i Remove the REAR COVERS See How To Remove Rear Covers See How To Remove Alternator Belt Loosen six 6 mounting bolts on the ALTERNATOR SUPPORT BRACKET Push this bracket up to remove tension on the DRIVE BELT and remove the drive belt Remove four 4 bolts from the CRANKSHAFT PULLEY ASSEMBLY by removing four 4 mounting bolts at the PILLOW BLOCK BEARINGS Replace components on the crankshaft pulley assembly as necessary Install new crankshaft pulley in reverse order Crankshaft Crankshaft Plate Washer Pulley Crankshaft w Plate Main Drive Belt New 170 ft los Used 160 ft lbs Pillow Block Pillow Bock Bearing Nuts Bearing and Washers Pillow Block Torque 30 35 ft lbs Bearing Bolts Life Fitness Model 8500 9100 9500HR Cross Trainers How To Replace The Intermediate Pulley Tools required 3 8 Socket set and Standard wrench set 1 Remove the REAR COVERS See How To Remove Rear Covers Loosen the ALTERNATOR PIVOT BOLT and rotate the alternator down to relieve belt tension Loosen the belt tension on the INTERMEDIATE

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