Life Fitness 90X Service Manual
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Life Fitness 90X Service Manual

Life Fitness 90X Service Manual

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Cross-Trainers 90X, 93X, 95Xe, and 95Xi
Fixed Stride Units
Customer Support Services
SERVICE MANUAL

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  • Page 1 Cross-Trainers 90X, 93X, 95Xe, and 95Xi Fixed Stride Units Customer Support Services SERVICE MANUAL...

  • Page 2: General Contents

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi GENERAL CONTENTS INTRODUCTION .......................ii SPECIAL SERVICE TOOLS .....................iii GLOSSARY ........................iv SECTIONAL CONTENTS TROUBLESHOOTING DIAGNOSTICS LED DIAGNOSTICS LCD HOW TO…SERVICE ELECTRONICS MISCELLANEOUS...
  • Page 3 If you do not have a part in stock, a form to order by FAX has been included in Section V for your convenience or you can call Life Fitness Customer Support Services any Monday through Friday from 8:00 AM to 6:00 PM (CST).
  • Page 4 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SPECIAL SERVICE TOOL REQUIREMENTS Unless otherwise specified, only basic hand tools are required to perform service procedures outlined in this section. Some of these standard tools should consist of: Philips and Straight-Blade Screw Drivers, Torx Set, Pliers, Rubber Mallet, Pry Bar, Snap Ring Pliers (internal and external), Standard and Metric size Socket Set (3/8 or 1/2 drive), and Standard and Metric size Combination, open-end, or Box Wrenches.
  • Page 5 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi GLOSSARY The following words and acronyms are commonly referred to throughout this manual. Take time to familiarize yourself with them. Electrical plugs used to connect wiring into electrical component. Connectors Electronic board for making settings and monitoring physical output.

  • Page 6: Table Of Contents

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SECTION I TROUBLESHOOTING GUIDE PAGE No Power..........................3 Console Lights and Then Fails.................... 3 No Leds or Random Leds Lit On Display ................3 Unit Autostarts But Does Not Read Rpm ................3 Unit Does Not Autostart.......................
  • Page 7 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...

  • Page 8: Troubleshooting Guide

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION No Power Faulty Battery Using Multi-meter, verify that battery the Voltage is greater than 6 Volts DC. Replace battery if voltage is below 6 volts DC...

  • Page 9: Unit Does Not Autostart

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Unit does not Auto Start Faulty Battery Using Multi-meter, verify that battery the Voltage is greater than 6 Volts DC. Replace battery if voltage is...

  • Page 10: Erratic Heart Rate From Lifepulse Sensors

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Erratic Heart Rate from Life Pulse Life Pulse sensors dirty from Clean Life Pulse Sensors with mild sensors usage or from being cleaned soap and water. Replace sensors if with incorrect solution condition warrants.

  • Page 11: Erratic Heart Rate Using Polar Transmitter

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION No Heart Rate reading using Polar Transmitter is not making good Reposition transmitter on chest. transmitter. (Telemetry equipped units contact with body or positioned Moisten transmitter for better contact only).

  • Page 12: Screen Is Blank

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Screen is blank LCD Back-Light Replace/reconnect LCD/Touch Screen. Back-Light Power Inverter bad Replace/reconnect back-light inverter. LCD Screen failure Replace/reconnect LCD/Touch Screen. Problem on the Single Board Replace Single Board Computer.

  • Page 13: Testing The Inverter Board

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE – TESTING THE INVERTER BOARD Special Service Tools Required: Multi-meter CAUTION! HIGH VOLTAGE ON CONNECTORS J2 AND J3 Test Points 1. Remove the Entertainment System Console from the Unit. 2. Remove Rear Cover from the Console Assembly.

  • Page 14: Testing The Power Supply Cable

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TROUBLESHOOTING GUIDE – TESTING THE POWER SUPPLY CABLE Special Service Tools Required: Multi-meter Positive 1. Unscrew the Retaining Nut securing the Power Cable Plug. Remove the Cable. 2. Using a Multi-meter, touch the Red Lead to the...

  • Page 15: Notes

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...
  • Page 16 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SECTION IIA DIAGNOSTIC MODES FOR LED UNITS Page 90x Console ......................3 93x Console ......................4 95xi Console ......................5 Map......................... 6 Entry Level ......................7 Test/Service - All Leds And Keypad Test..............8 Test/Service - Walking Led Test ................
  • Page 17 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...

  • Page 18: Console

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi 90X Display Console...
  • Page 19 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi 93X Display Console...
  • Page 20 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi 95Xi Display Console...

  • Page 21: Map

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi...

  • Page 22: Entry Level

    CODE VER X.XX Hold down the number 5 key on (95Xi and 97Xi) or the UP ARROW key on (90X and 93X) units, then press the CLEAR key twice. Each press of the UP ARROW key will show the folllowing: CODE VERSION…………………………ex: CODE VER - X.XX...

  • Page 23: Test/Service All Leds And Keypad Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE ALL LEDS AND KEYPAD TEST XXXXXXXXXXXXXXXXXX XXXXX On entry into this state, all of the LED’s will turn ON. Pressing the keys will result in a beep sound for all but the START, ENTER and CLEAR keys, a character repeated across the message center will be displayed.

  • Page 24: Test/Service - Walking Led Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE – WALKING LED TEST On entry to this state, the LED segments in the MESSAGE CENTER and the PROFILE WINDOW will give the animated effect of moving, henceforth, “Walking LED”. Press the ENTER key to advance to the next diagnostic state. Press the CLEAR key to go back...

  • Page 25: Test/Service - Miscellaneous 1 Test

    97Xi and the Up and Down arrow keys on the 90X and 93X. Pressing the Aerobics Mode key will toggle the speaker ON and OFF. (Not available on 90X). Pressing the ‘0’ key ( 95Xi and 97Xi ) will toggle the RPM display between the alternator RPM and Reed Switch RPM.

  • Page 26: Test/Service - Miscellaneous 2 Test

    The present alternator RPM will be displayed in the RPM window. Pressing the ‘5’ key (95Xi and 97Xi) or the Down Arrow key ( 90x and 93X) will display the value of Vsys at startup ( before the alternator is turned on). This is useful because you can get an indication of the battery voltage of the 6v battery.

  • Page 27: Test/Service - Port I/O Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE – PORT I/O TEST RELAY FLD KICK Press the ENTER key to advance to the next diagnostic state. Press the CLEAR key to go back to the previous diagnostic state. Press the CLEAR key repeatedly to exit diagnostics.

  • Page 28: Test/Service - Life Pulse Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE – LIFE PULSE TEST C-O G99 Upon initial entry to this test, a heart will be displayed in the profile window along with two messages in the message center. The first indicates the Life Pulse software version number. The second is a message concerning the configuration of the Life Pulse communication system being ON or OFF.

  • Page 29: Test/Service - Csafe Network Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE – CSAFE NETWORK TEST NOT CONNECTED Within this state, the CSAFE network can be tested. This is how you can check to see if you’re receiving any communications from the network system.

  • Page 30: Test/Service - Eeprom Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE – EEPROM TEST EEPROM TEST - This diagnostic state tests the Display Console EEPROM by reading, writing and replacing all used locations in the Display Console EEPROM. The EEPROM location being tested will appear in the display message center.

  • Page 31: Test/Service - Telemetry Enable/Disable

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE – TELEMETRY ENABLE/DISABLE TELEMETRY ON Within this state the TELEMETRY can be turned ON or OFF. If a telemetry heart rate is detected, it will be displayed when telemetry is set to ON.

  • Page 32: Test/Service - Language

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi TEST/SERVICE - LANGUAGE LANG . = ENGLISH Within this state one of seven languages can be selected. They are: English, German, French, Italian, Dutch, Spanish and Portuguese. The UP ARROW, when pressed, displays the next language in the list.

  • Page 33: Optional Settings - Max Program Duration

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – MAX PROGRAM DURATION MAX DURATION 60 Within this state the MAXIMUM PROGRAM DURATION is displayed and can be adjusted from a range of 10-99 minutes. The DOWN ARROW will decrease the value by 1 minute. Key will auto-repeat if held.

  • Page 34: Optional Settings - English/Metric Units

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – ENGLISH/METRIC UNITS ENGLISH UNITS Within this state ENGLISH or METRIC units can be selected. The DOWN arrow will select METRIC units. The UP arrow will select ENGLISH units. The ENTER key LED indicates when the value is at the default setting of ENGLISH UNITS. This value is stored in EEPROM and is kept when the unit is not in use.

  • Page 35: Optional Settings - Watt Display Enable/Disable

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – WATTS DISPLAY ENABLE/DISABLE WATT DISPLAY ON If this option is enabled the MESSAGE CENTER displays the Watts equivalent of the workload. This message will only be displayed after a level change.

  • Page 36: Optional Settings - Mets Display Enable/Disable

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – METS DISPLAY ENABLE/DISABLE METS DISPLAY ON If this option is enabled the MESSAGE CENTER displays the MET’s equivalent of the workout. This message will only be displayed after a level change.

  • Page 37: Optional Settings - Cal/Hr Display Enable/Disable

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – CAL/HR DISPLAY ENABLE/DISABLE CAL/H DISP. ON If this option is enabled the MESSAGE CENTER displays the Calories/Hour equivalent of the workload. This message will only be displayed after a level change.
  • Page 38 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – TOTAL HOURS AND STATISTICS HOUR = Upon entry to this state TOTAL HOURS are displayed. STATISTICS can be displayed using the UP and DOWN arrow keys. The UP arrow allows scrolling through the available programs and shows the number of times each program has been selected.
  • Page 39 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – ENTERTAINMENT CONTROLS ON/OFF ENTERTAIN The UP and DOWN arrow keys will turn ON or OFF channel and volume controls for third party entertainment systems. (Such as Cardio Theater ). The factory default setting is OFF.

  • Page 40: Optional Settings - Photo Shoot

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi OPTIONAL SETTINGS – PHOTO SHOOT 135 1.09 62 17:44 Data displayed in the MESSAGE CENTER is non-functional and intended only to simulate values for photographic sessions. This is the final diagnostic state.

  • Page 41: Notes

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...
  • Page 42 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SECTION IIB DIAGNOSTIC MODES 95Xe LCD UNITS Welcome Screen ....................... 3 Workout Screen ......................... 4 Main Menu ......................... 5 System Test Menu ......................6 System Diagnostics......................7 Test Engineering ........................ 8 Telemetry Test ........................9 LifePulse Test ........................

  • Page 44: Welcome Screen

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE WELCOME SCREEN LCD Console Welcome Screen The Welcome Screen initially appears after Power-Up or when the bike is not in use. Touching the Screen will change the screen to the WORKOUT SELECTION screen.

  • Page 45: Workout Selection Screen

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE WORKOUT SELECTION SCREEN From the Workout Selection Screen you will be able to enter the Systems Option Menu. To enter, go to the Workout Selection Screen then press and hold the COOLDOWN key, and then double-tap the Life Fitness icon.
  • Page 46 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE SYSTEM OPTIONS – MAIN MENU The System Options - Main Menu selections, when pressed, allows access to the System Test Menu, Information Menu, and Configuration Menu. Pressing the screen Exit key will return you back to the Workout Selection Screen.

  • Page 47: System Test Menu

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE SYSTEM TEST MENU The System Test Menu allows the user to access the above by pressing the appropriate key. Press the screen Back key will return you to the System Options – Main Menu screen.

  • Page 48: System Diagnostics

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE SYSTEM DIAGNOSTICS Entry to this screen allows the user to view the following: SYSTEM VOLTAGE Displays system voltage present at console. ALTERNATOR VOLTAGE Displays voltage output from alternator Displays the Pedal Lever RPMs from the Alternator.

  • Page 49: Test Engineering

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE TEST ENGINEERING All status windows on this screen should display OFF and should not be changed unless instructed to do so by Life Fitness Customer Support. Pressing the screen Back key will return you to the System Diagnostics screen.

  • Page 50: Telemetry Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE TELEMETRY TEST The circles in the Telemetry Box indicate whether Telemetry is Enabled or Disabled. Touching the appropriate circle can enable or disable Telemetry. The Heart rate value window will display the users Heart Rate when Telemetry is enabled.

  • Page 51: Lifepulse Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE LIFE PULSE TEST The Lifepulse™ System can be tested manually. The system will display a “Hands-On” reading when the user has placed their hands on the Lifepulse™ Sensors. A timer will commence (and will show in the Acquisition Time window ) from the time both Hands-On condition occurs to when the LifePulse system can generate a heart rate reading.

  • Page 52: Csafe Network Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE CSAFE NETWORK TEST CSafe Test - Not Available at This Time.

  • Page 53: Eeprom Test

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE EEPROM TEST Pressing the screen EEPROM Internal Test key allows testing of the EEPROM on the Single Board Computer. Pressing the screen EEPROM External Test key allows testing of the EEPROM on the Interface Board.

  • Page 54: Information Menu

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE INFORMATION MENU STATISTICS Displays various historical data regarding individual workout program usage and critical system power levels. SOFTWARE VERSIONS Displays current software version information. SYSTEM ERRORS Displays historical information regarding system errors encountered during operation.

  • Page 55: Information Statistics

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE INFORMATION STATISTICS Entry to this screen allows to user to view statistics such as: total hours of use on the unit and hours of use per program used along with other information.

  • Page 56: Software Versions

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE SOFTWARE VERSIONS Note: Values shown are for reference only. This screen allows the user to view the current software programs loaded into the unit along with its corresponding Life Fitness part number if applicable.

  • Page 57: System Errors

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE SYSTEM ERRORS This screen allows the user to view system errors that have been logged into the unit’s memory. Pressing the screen Back key will return you to System Options – Main Menu screen. Pressing the screen MAIN...

  • Page 58: Usage Log Report

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE USAGE LOG REPORT This screen allows the user to view detailed information in relation to RPMs used at different levels. Pressing the screen Back key will return you to System Options – Main Menu screen. Pressing the screen MAIN...

  • Page 59: Configuration Menu

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE CONFIGURATION MENU Supervisory workout parameter setup. MANAGER MANUFACTURER Critical system parameter setup. Television configuration. TOUCH SCREEN CONFIGURATION Proximity calibration of touched screen. Pressing the screen Back key will return you to System Options – Main Menu screen. Pressing the screen MAIN...

  • Page 60: Managers Configuration

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE MANAGER’S CONFIGURATION Maximum Workout Duration: Allows the manager to set a maximum workout limit between 1 and 99 minutes. The time can be modified using the up or down arrow keys. The unit default is 60 minutes.

  • Page 61: Custom Message Setup

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE CUSTOM MESSAGE SETUP This configuration allows for a custom message to be displayed across the Welcome Screen. Creating/changing a Custom Message—after entering the Manager’s Configuration, check to make sure that Custom Message is enabled, and then select Custom Message Setup.
  • Page 62 LCD DISPLAY CONSOLE MANUFACTURERES CONFIGURATION MENU Access to this screen will only be available to Life Fitness certified technicians. Pressing the screen Back key will return you to System Options – Main Menu screen. Pressing the screen MAIN MENU key will return you back to the MAIN MENU.

  • Page 63: Tv Set Up

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE TV SET UP This screen brings up the TV screen and allows adjustment of brightness, contrast, saturation and hue. Also allows the choice of TV format, antenna setup and channel setup. To Set up channels: Select Auto in Channel Setup and then press Start.

  • Page 64: Max Volume Setup

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE MAX VOLUME SETUP Entry to this screen allows the user to adjust Volume by using the Arrow keys. Note: Headphones must be used for this function. The upper set of arrows adjusts the volume capacity higher or lower, allowing clubs to compensate for average noise levels within the club.

  • Page 65: Touch Screen Configuration

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD DISPLAY CONSOLE TOUCH SCREEN CONFIGURATION Entry into this screen will allow to user to reconfigure the Touch Screen. The display will show a blank screen with a + sign in the middle. Follow the directions at the top of the screen to properly reconfigure the Touch Screen. This procedure may have to be repeated more than once.
  • Page 66 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SECTION III HOW TO…SERVICE AND REPAIR Page Console Support Cover ........................3 Console Assembly ..........................4 Accessory Tray ..........................5 Console Support ..........................6 Bullhorns ............................7 Deadshaft Covers ..........................8 Handlebars............................9 Lifepulse Sensors ..........................
  • Page 67 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi NOTES...

  • Page 68: Console Support Cover

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Console Support Cover Special Service Tools Required: NONE 1. Remove the Console Support Cap by squeezing the sides and pulling it away from the Console Support. 2. Remove the two Phillips screws securing the Console Support Cover to Console Support.

  • Page 69: Console Assembly

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Console Assembly Special Service Tools Required: NONE Console 1. Remove the Console Support Cover. See Assembly “How To…” in this section. 2. Remove the four Phillips screws securing the Console to the Console Support.
  • Page 70 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Accessory Tray Special Service Tools Required: NONE 1. Remove the Console Support Cover. See “How To…” in this section. Console 2. Remove the Console. See “How To…” in this Assembly section.

  • Page 71: Accessory Tray

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Console Support Bracket Special Service Tools Required: NONE 1. Remove the Console Support Cover. See “How To…” in this section. Console Assembly 2. Remove the Console. See “How To…” in this section.

  • Page 72: Bullhorns

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Bullhorns Special Service Tools Required: NONE 1. Remove the Phillips screw securing the Bullhorn Cover to the Bullhorn. 2. Remove the two Allen bolts securing the Bullhorn to the Deadshaft.
  • Page 73 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Deadshaft Covers Special Service Tools Required: NONE 1. Remove the two screws securing Deadshaft Covers to each other. 2. Install the new Deadshaft Covers in reverse order. Note: Make sure the Heart Rate cables, if present, do not get pinched when installing the covers.

  • Page 74: Handlebar Assembly

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Handlebars Special Service Tools Required: NONE 1. Remove the Outside Deadshaft Covers. See “How To…” in this section. 2. Remove three Allen bolts securing the Handlebar to the end of the Deadshaft.

  • Page 75: Lifepulse Sensors

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the LifePulse Sensors Special Service Tools Required: NONE 1. Remove the two screws securing the LifePulse sensors to the Handlebar. LifePulse Handle Sensor 2. Disconnect the Heart Rate Cable from the Grip LifePulse sensors.

  • Page 76: Front Frame Cover

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Front Frame Cover Special Service Tools Required: NONE 1. Remove the two screws securing the Front Frame Cover to the Frame. 2. Slide the Front Frame Cover forward until free of the Ladder Frame Cover.
  • Page 77 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Main Shroud Special Service Tools Required: NONE 1. Remove the four Phillips screws (two on each side) securing the Main Shroud to the Drive Frame Assembly. Screws 2. Remove the Main Shroud by lifting them straight up.

  • Page 78: Ladder Frame Cover

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Ladder Frame Cover Special Service Tools Required: NONE 1. Remove the Front Frame Cover. See “How To…” in this section. Ladder 2. Remove the Main Shrouds. See Frame Cover “How To…”...
  • Page 79 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Console Cable Assembly Special Service Tools Required: NONE 1. Remove the Front Frame Cover. See “How To” in this section. 2. Remove the Main Shroud. Main Cable See “How To” in this section.

  • Page 80: Lower Shroud Panels

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Lower Shroud Panels Special Service Tools Required: NONE 1. Remove the two Phillips screws securing the Lower Shroud Panels to the Drive Frame Assembly. 2. Install new Lower Shroud Panels in reverse order.
  • Page 81 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Outer Lever Joint Cover and Rocker Arm Cover Special Service Tools Required: NONE 1. Remove the Phillips screw securing the Outer Rocker Cover to the Inner Rocker Cover.
  • Page 82 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace Inner Lever Joint Cover and Inner Rocker Arm Cover Special Service Tools Required: NONE 1. Remove the Outer Lever Joint and Rocker Arm Covers. See “How To…” in this section.

  • Page 83: Rocker Arm

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Rocker Arm Special Service Tools Required: NONE 1. Remove the Outer Deadshaft Covers. See “How To…” in this section. 2. Remove the Handlebar. See “How To…” in this section.

  • Page 84: Outer Link Cover

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Outer Link Cover Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. 2. Remove the six Phillips screws (three at the top, three at bottom) securing the Outer Link Cover to the Inner Link Cover.

  • Page 85: Pedal Lever Assembly

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Pedal Lever Assembly Special Service Tools Required: NONE Crankarm Extension Bolt Shaft Collar Crankarm Extension 1. Remove the Main Shrouds. See “How To…” in this section. 2. Remove the Outer Link Cover. See “How To…” in this section.

  • Page 86: Control Link Assembly

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Control Link Assembly Special Service Tools Required: NONE Control Link Assembly Crank Extension Mounting Bolt Hex nut 1. Remove the Main Shrouds. See “How To…” in this section.
  • Page 87 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Roller Assembly Special Service Tools Required: NONE Mounting holes for Dynamic Link Assembly 1. Remove the Main Shrouds. See “How To…” in this section. Mounting 2. Remove the Outer Link Cover. See “How To…”...

  • Page 88: Crankarm Cover

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace Crankarm Cover Special Service Tools Required: NONE Crankarm Cover Mounting screws Crankarm Cover 1. Remove the Main Shroud. See “How To…” in this section. 2. Remove the Outer Link Cover. See “How To…” in this section.

  • Page 89: Main Drive Belt

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Main Drive Belt Special Service Tools Required: NONE Main Drive Belt Crossover Shaft Crank Pulley Left Crankarm Weld Assembly 1. Remove the Main Shrouds. See “How To…” in this section.

  • Page 90: Battery

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To… Replace the Battery Tools Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. 2. Disconnect the Red and Black wires from the Battery.

  • Page 91: Reed Switch And Cable

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To… Replace the Reed Switch Cable Assembly Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. 2. Disconnect the Reed Switch Cable from the Power Control Board.

  • Page 92: Power Control Board

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To… Replace the Power Control Board Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. 2. Tag and identify wiring at Power Control Board, and then disconnect from the Power Control Board.

  • Page 93: Alternator Belt

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To… Replace the Alternator Belt Special Service Tools Required: NONE Alternator 1. Remove the Main Shrouds. See “How To…” in this section. 2. Walk the Alternator Belt off the Poly-V Pulley and remove the Belt.
  • Page 94 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To… Replace the Poly-V Pulley Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. Crossover Shaft 2. Remove the Right Lower Panel Shroud. See “How To…” in this section.

  • Page 95: Alternator

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Alternator Special Service Tools Required: NONE Mounting Bolts 1. Remove the Main Shrouds. See “How To…” in this section. 2. Walk the Alternator Belt off of the Poly-V Pulley...

  • Page 96: Pedal

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Pedal Special Service Tools Required: NONE Pedal Pedal Bolts 1. Remove the four Torx bolts securing the Pedal to the Pedal Lever Assembly. 2. Re-install the new Pedal in reverse order.

  • Page 97: Resistors

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Resistors Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. 2. Remove the Lower Shroud Panels. See “How To…” in this section.
  • Page 98 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Magnet and Standoff Assembly Special Service Tools Required: NONE 1. Remove the Main Shrouds. See “How To…” in this section. 2. Remove the Left Outer Link Cover. “How To…” in this section.

  • Page 99: Right Crankarm

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Right Crankarm Special Service Tools Required: NONE Crankshaft/Pulley Assembly Machine Key Hex bolt Hex Nut Set screw Right Crankarm 1. Remove the Main Shrouds. See “How To…” in this section.
  • Page 100 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To… Replace the Crankshaft and Pulley Assembly Special Service Tools Required: NONE Left Crankarm Weld Assembly Crank Pulley Crankshaft Plate Bolts Main Drive Belt 1. Remove the Main Shrouds. See “How To…” in this section.
  • Page 101 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Pedal/Rocker Shaft Bearings Special Service Tools Required: BEARING TOOL KIT 1. Remove the Front and Rear Deadshaft Covers. 2. Remove three bolts securing Handlebar to Screws Rocker Arm and remove the Handlebar. If equipped, disconnect the Heart Rate Cable.
  • Page 102 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Pedal/Rocker Shaft Bearings – Continued Special Service Tools Required: BEARING TOOL KIT 7. Install the bearing puller on the Rocker Arm as shown. 8. Press-out the needle bearings by rotating the hex nut Clockwise until the bearings drop into puller.
  • Page 103 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Pedal/Rocker Shaft Bearings – Continued Special Service Tools Required: BEARING TOOL KIT 10. Position the new needle bearings and bearing tool as shown. Make sure bearings are aligned and squared with the bearing markings, which should be facing outward.
  • Page 104 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crossover Shaft and Bearings Special Service Tools Required: BEARINGTOOLKIT Note: Replace the Crossover Shaft at the same time Bearings are replaced. Screws 1. Remove screws securing Main Shrouds to frame.
  • Page 105 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crossover Shaft & Bearings – Continued Special Service Tools Required: BEARING TOOLKIT Alternator Drive Belt Belt Poly-V Pulley Thrust Thrust Crossover Pulley Washer Washer Screw and Shaft Washer Setscrews(2) 3.
  • Page 106 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crossover Shaft & Bearings – Continued Special Service Tools Require: BEARING TOOLKIT 9. Install bearing puller on drive frame as shown. 10. Press out the needle bearings by rotating the hex nut Clockwise until the bearings drop into the puller hub.
  • Page 107 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crossover Shaft and Bearings – Continued Special Service Tools Require: BEARING TOOLKIT Clean the housing before installing new needle bearings. Position the new needle bearings and bearing tool as shown. Make sure bearings are aligned and square, with bearing markings facing outward.
  • Page 108 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crank Shaft and Bearings Special Service Tools Require: BEARING TOOLKIT Note: Replace both Crank Shaft and Bearings. 1. Remove the Outer Lever Joint and Rocker Arm Covers from the Pedal Arm and Rocker Arm Joint.
  • Page 109 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crank Shaft and Bearings – Continued Special Service Tools Require: BEARING TOOLKIT 10. Install Bearing Puller on the Drive Frame as shown. 11. Press out the Needle Bearings by rotating the Hex Nut clockwise until the bearings drop into the puller hub.
  • Page 110 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To...Replace the Crank Shaft and Bearings – Continued Special Service Tools Require: BEARING TOOLKIT 13. Position the new Needle Bearings and Bearing Tool as shown. Make sure bearings are aligned and square with bearing markings facing outward.

  • Page 111: Lcd Integrated Console Overview

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi LCD Integrated Console Overview Special Service Tools Required: NONE CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO THE MACHINE USING AN ANTI-STATIC GROUND STRAP. NOTE: The following pages provide service procedures for servicing the LCD Integrated Console. While the Console Housings may differ between the various products, the internal components, which make up the Console, are identical.

  • Page 112: Console Assembly

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Headphone Jack Special Service Tools Required: NONE CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO THE MACHINE USING AN ANTI-STATIC GROUND STRAP. Note: For clarity purposes the Console is shown off the unit.

  • Page 113: Back Cover

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Inverter Board Special Service Tools Required: NONE CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO THE MACHINE USING AN ANTI-STATIC GROUND STRAP. 1. Remove the console from the unit.

  • Page 114: Single Board Computer

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Single Board Computer Special Service Tools Required: NONE CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO THE MACHINE USING AN ANTI-STATIC GROUND STRAP. Single Board Computer Single Board...

  • Page 115: Interface Board

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Interface Board Special Service Tools Required: NONE CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO THE MACHINE USING AN ANTI-STATIC GROUND STRAP. 1. Remove console from unit. See “How To…”...

  • Page 116: Touch Screen Assembly

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi How To... Replace the Touch Screen Assembly Special Service Tools Required: NONE CAUTION! BEFORE REPLACING CIRCUIT BOARD(S), GROUND YOURSELF TO THE MACHINE USING AN ANTI-STATIC GROUND STRAP. Touch Screen 1. Remove the Console. See “How To…” in Assembly this section.
  • Page 117 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi NOTES...
  • Page 118 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SECTION IV ELECTRONICS WIRING DIAGRAMS Page Wiring Block Diagram – Models 90x And 93x ..............3 Wiring Block Diagram – Model 95xi ..................4 Wiring Block Diagram – Model 95xe ................... 5 Notes ........................... 6...
  • Page 119 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...
  • Page 120 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi WIRING BLOCK DIAGRAM - MODELS 90X AND 93X Power Control Board B084-92218-D000 Console PCB A084-92220-A008...
  • Page 121 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi WIRING BLOCK DIAGRAM - MODEL 95Xi POWER CONTROL BOARD *ORANGE B084-92218-D000 12POS.MNL POWER RES. #RED/BLK 2 x .75 OHM RPM_ALT #RED/BLK 240W ValtR #RED/BLK ACTAP Valt #GREEN ValtR #GREEN ValtR #GREEN ValtR...
  • Page 122 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi WIRING BLOCK DIAGRAM – MODELS 95Xe PENDING...
  • Page 123 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi NOTES...
  • Page 124 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi SECTION V MISCELLANEOUS Page Model Identification and Serial Number Location..............3 Preventive Maintenance Tips ....................4 Safety Instructions....................... 5 Notes ........................... 6...
  • Page 125 Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...

  • Page 126: Model Identification And Serial Number Location

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Serial Number Tag...

  • Page 127: Preventive Maintenance Tips

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi PREVENTIVE MAINTENANCE TIPS Preventive Maintenance Schedule DAILY MONTHLY BI-ANNUALLY Housing Inside Clean Outside Clean Power Control Heatsink Clean Connectors Inspect Board Inspect Console Assembly Overlay Clean Mounting Bolts Inspect Connectors Inspect Alternator...

  • Page 128: Safety Instructions

    ⇒ 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.

  • Page 129: Notes

    Life Fitness Cross-Trainers 90X, 93X, 95Xe, and 95Xi Notes...
  • Page 130 © 2004 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.

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