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Life Fitness Model 9500 Series Cross-Trainers Customer Support Services SERVICE MANUAL...
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HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES Note: This service manual is applicable to Life Fitness model 9500 Lower Body and 9500HR Total Body Cross-Trainers. The Service Manual provides instruction, guidance and recommendations on safe and efficient approaches to repair and adjustment situations.
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Life Fitness Model 9500 Series Cross-Trainers THEORY OF OPERATION The electronics system of the CT-9500 Series Cross-Trainers, is made up of three distinct modules, the Power Entry Module, the Display Console, and the Power Control Board. 120 volts AC enters the Power Entry Module. It passes through a transformer and is converted to 14 volts AC.
Life Fitness Model 9500 Series Cross-Trainers TABLE OF CONTENTS SECTION I TROUBLESHOOTING GUIDES PAGE LOUD THUMPING NOISE ....................2 RUBBING AND WHINNING NOISE................. 2 METAL NOISE......................... 2 GRINDING........................2 RUBBING AND SQUEAKING ..................2 KNOCKING AND THUMPING..................2 DRIVE BELT SLIPPING....................2 UPPER ARMS LOOSE ....................
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Life Fitness Model 9500 Series Cross-Trainers TABLE OF CONTENTS SECTION III HOW T0…REPLACE: PAGE DISPLAY CONSOLE ASSEMBLY..................2 TRAY ASSEMBLY ......................3 READING RACK ASSEMBLY..................4 STOP SWITCH ASSEMBLY.................... 5 HOOD SHROUD ASSEMBLY..................6 HEART RATE UPPER ARM ASSEMBLY................. 7 UPPER ARM ASSEMBLY....................
Life Fitness Model 9500 Series Cross-Trainers Malfunction Probable Cause Corrective Action Loud thumping noise when Pulleys misaligned. Loosen the pillow block bearing, align the pedal levers rotate under load. pulleys and then retighten the pillow block bearings. Rubbing/whining noise when Dirt build up in pedal rails.
Life Fitness Model 9500 Series Cross-Trainers Malfunction Probable Cause Corrective Action Front to back play in pedal / Worn bearings. Check for front to back movement in bearings arm. that connect pedal lever and crank arm or in the 14” link.
Life Fitness Model 9500 Series Cross-Trainers Malfunction Probable Cause Corrective Action Erratic heart rate. User’s hands are not making Verify hands are contacting entire sensors. proper contact. Sweat is causing hands to slip Wipe hands and sensors. Bad connection. Sensor loose or falling off. Replace Life Pulse digital sensor with kit.
Life Fitness Model 9500 Series Cross-Trainers Malfunction Probable Cause Corrective Action Alternator belt tension. Loose alternator belt. Check tension. New belt should be tensioned to 90 FT LBS. Existing belt at 80 FT LBS. If gauges are not available, set to 1/4” (6mm) deflection.
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Life Fitness Model 9500 Series Cross-Trainers...
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Life Fitness Model 9500 Series Cross-Trainers SECTION II DIAGNOSTIC MODES...
Life Fitness Model 9500 Series Cross-Trainers OVERVIEW To access Diagnostic State 1, press and hold down HEART RATE PROGRAM: The heart rate program the number 5 key while pressing the CLEAR/PAUSE version is displayed in the ELAPSED TIME window key twice.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 1 - ALL LEDs AND KEYPAD TEST To access Diagnostic State 1, press and hold down the number 5 key while pressing the CLEAR/PAUSE key twice. All the LEDs should illuminate on the status displays. Pressing each numeric key will display its value across the status screen.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 2 - INDIVIDUAL LED TEST This test will show the LEDs for each display segment (Time, Speed RPM, Level, Heart Rate, Calories, Distance, CAL/Watts, and Watts) for proper illumination. Press the START/ENTER key to scroll forward to the next Diagnostic State or press the CLEAR/PAUSE key to scroll backward to Diagnostic State 1.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 3 - PROGRAM VERSION NUMBER P 3 . 1 1 The current PROGRAM VERSION NUMBER (ex: P285) will be displayed in the TIME window. While striding, the RPM will be displayed in the RPM window, and while holding the handlebar sensors or wearing an optional telemetry heart rate chest strap, the HEART RATE will be displayed in the LEVEL window.
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Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTICS STATE 3 - VERSION #: RPM, HR, and LOAD TESTS w/ Integrated PCB P1 .20 REDY The PROGRAM VERSION NUMBER (ex. P1.01) will be displayed in the ELAPSED TIME window. The present RPM will be displayed in the RPM window.
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Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 4 - HEART RATE SOFTWARE (Model 9500HR ONLY) P1 .80 P4.00 N O N E The PROGRAM VERSION NUMBER (P1.80) of the HEART RATE DSP board software is displayed in the ELAPSED TIME window.
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Life Fitness Model 9500 Series Cross-Trainers w/ Integrated DIAGNOSTICS STATE 4 - LIFEPULSE and NETWORK STATUS TESTS L P V E R S I O N Upon entry to this diagnostic state, the LifePulse software version number is displayed for 2 seconds. After this, the LP Comm Status is displayed for 2 seconds, which will either display ‘LP PC COMM ON’...
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 5 - MAXIMUM PROGRAM DURATION MAX DURATI O N PROGRAM DURATION is used to set a length of time. Time is adjustable between 10 to 99 minutes. Press the DOWN ARROW to decrease time in increments of 1 minute. Press the UP ARROW to increase the time in increments of 1 minute.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 6 - TELEMETRY ENABLE/DISABLE TELEM E T R Y TELEMETRY can be turned ON or OFF. The telemetry default is set to ON. When in the default mode the START/ENTER key LED will illuminate. This setting is stored in EEROM even when the unit is not in use. The heart-shaped LEDs illuminate in the program profile window.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 7 - ENGLISH / METRIC UNITS E N G L I S H U N I T S To select ENGLISH or METRIC units, press the number 5 key or the arrows keys (DOWN ARROW for Metric and UP ARROW for English).
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 8 - MODEL SELECTION 9500HR For model selection, press the number 5 key or the arrow keys. The START/ENTER key LED illuminates when the default model is selected. This setting is stored in the EEPROM when the unit is not in use.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 9 - TOTAL HOURS / STATISTICS H O U R S = This program shows the TOTAL HOURS for all programs (Hill, Random, Manual, Fat, Cardio...), as well as total individual hours for each program.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 10 - METS ENABLE / DISABLE M E TS The METS state shows the work load (optional). Within this state, the METS OPTION can be turned ON or OFF. Press the number 5 key or the arrow keys to METS ON or METS OFF. The DOWN ARROW turns OFF METS and the UP ARROW turns ON METS.
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Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 11 - PAUSE TIMEOUT DURATION P A U S E I M E O U T The PAUSE TIME-OUT can be adjusted between 1 through 99 minutes. The number 1 key or DOWN ARROW are used to decrease the setting in increments of one minute.
Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 12 - PHOTO SHOOT 28.45 1 35 Photo Shoot is used primarily for photography purposes in order to develop sales and marketing literature, training, and for customer support. The sample data in each field is non-functional and used for display purposes only.
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Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTICS STATE 12 – LANGUAGE SELECTION w/ Integrated PCB LANG Within this state, the LANGUAGE can be changed to any one of 7 languages, including English, German, French, Italian, Dutch, Spanish or Portuguese. The ‘UP ARROW’ will display the next language in the list.
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Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTICS STATE 13 – EEPROM TEST w/ Integrated PCB EEPRO M TEST Within this state, EEPROM can be tested. Pressing the ‘DOWN ARROW’ will initiate the EEPROM test. If the test completes successfully, the message ‘EEPROM GOOD’...
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Life Fitness Model 9500 Series Cross-Trainers DIAGNOSTIC STATE 14 - PHOTO SHOOT w/ Integrated PCB 28.45 1 35 This state is to be used only for PHOTO SHOOT. None of the data items displayed are real. Sleep timers are disabled.
Life Fitness Model 9500 Series Cross-Trainers How To... Replace the Display Console Assembly Tools required: Phillips screwdriver Display Console 1. Turn the power OFF at the ON/OFF switch and unplug the ac line cord from the electrical outlet. 2. Remove the four SCREWS securing the DISPLAY CONSOLE to the MONO-COLUMN ASSEMBLY.
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Life Fitness Model 9500 Series Cross-Trainers How To... Replace the Tray Assembly Tools required: Socket set or Open end wrench, Phillips screwdriver 1. Turn power OFF at the ON/OFF switch and unplug ac line cord from electrical outlet. 2. Remove the SCREWS (4) securing the DISPLAY CONSOLE to the MONO-COLUMN ASSEMBLY.
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Life Fitness Model 9500HR Cross-Trainer How To... Replace the Reading Rack Assembly Tools required: Socket set or Open end wrench 1. Turn power OFF at the ON/OFF switch. 2. Remove the SCREWS (4) securing the READING RACK to the MONOCOLUMN.
Life Fitness Model 9500 Series Cross-Trainers How To... Replace the Stop Switch Assembly Tools required: Standard screwdriver, Pliers, Socket set or Open end wrench, Phillips screwdriver 1. Turn power OFF at the ON/OFF switch and unplug ac line cord from electrical outlet.
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Life Fitness Model 9500 Series Cross-Trainers How To... Replace the Hood Shroud Assembly Tools Required: Torx key, or Standard flat screwdriver, Socket Set, Hex Key Set 1. Turn power OFF at the On/Off switch and unplug the AC line cord...
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Life Fitness Model 9500HR Cross-Trainer How To... Replace Heart Rate Upper Arm Assembly Tools Required: Phillips screwdriver, Socket Set 1. Turn power OFF at the ON/OFF switch and unplug AC line cord from the electrical outlet. 2. Remove SCREWS (2) securing the ARM CAP SHROUD.
Life Fitness Model 9500 Cross-Trainer How To... Replace Upper Arm Assembly Tools Required: Phillips screwdriver, Socket Set Reading Rack 1. Turn power OFF at the ON/OFF switch and unplug AC line cord from electrical outlet. Screw Upper Arm 2. Remove two SCREWS securing the ARM CAP...
Life Fitness Model 9500HR Cross-Trainer How To...Replace Right Side Shroud For Heart Rate Units Tools Required: Torx key, or Standard flat screwdriver, Socket Set, Hex Key Set 1. Turn power OFF at the On/Off switch and unplug line cord from electrical outlet.
Life Fitness Model 9500 Cross-Trainer How To... Replace Right Side Shroud For Non-Heart Rate Units Tools Required: Torx key, or Standard flat screwdriver, Socket Set, Hex Key Set 1. Turn power OFF at the On/Off switch and unplug line cord from electrical outlet.
Life Fitness Model 9500 Series Cross-Trainers How To... Replace the IDLER PULLEY TENSION BRACKET Tools Required: Two 9/16 inch wrenches or sockets WARNING: TURN THE POWER OFF AT THE ON/OFF SWITCH AND DISCONNECT THE PLUG FROM THE ELECTRICAL OUTLET PRIOR TO SERVICING ANY MACHINE OPERATING ON AC CURRENT.
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Life Fitness Model 9500 Series Cross-Trainers How To... Replace Drive Belt Tools required: Hex Key Set, Open End Wrench, Socket Set, Flat Blade and Phillips screwdriver WARNING: FAILURE TO OBSERVE SAFE PROCEDURES WHEN SERVICING THIS UNIT COULD RESULT IN INJURY AND OR ELECTRICAL SHOCK.
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Life Fitness Model 9500 Series Cross-Trainers How To... Replace Drive Belt (Continued) Using a hex key (1/8”) loosen and remove the SET SCREWS (2) in the PILLOW BLOCK BEARINGS. Using two wrenches (9/16’), remove the NYLON LOCK NUTS (2), BOLTS (2), and WASHERS, securing the user’s right side PILLOW BLOCK to the FRAME.
Life Fitness Model 9500 Series Cross-Trainers How To...Replace Power Control Board Bracket Assembly Tools Required: Torx screwdriver, Side cutter pliers, Phillips screwdriver 1. Turn power off at the ON/OFF switch and unplug ac line cord from electrical outlet. 2. Remove HOOD SHROUD ASSEMBLY. (See “How To...”) 3.
Life Fitness Model 9500 Series Cross-Trainers How To... Replace Alternator Tools Required: Torx key, or Standard flat screwdriver, Socket Set, Hex Key Set 1. Turn power OFF at the On/Off switch and unplug line cord from electrical outlet. 2. Remove HOOD SHROUD ASSEMBLY. (See “How To ...”) NOTE: NOTE THE POSITION OF WIRE CONNECTIONS ON ALTERNATOR BEFORE REMOVAL.
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Life Fitness Model 9500 Series Cross-Trainers How To... Replace Alternator Belt Tools Required: Torx key, or Standard flat screwdriver, Socket Set, Hex Key Set 1. Turn power OFF at the On/Off switch and unplug line cord from electrical outlet. 2. Remove HOOD SHROUD ASSEMBLY. (See “How To...”) 3.
Life Fitness Model 9500 Series Cross-Trainers How To... Replace Pedal Lever Assembly Tools required: Torx screwdriver (T20), Socket set, Open end wrench set Turn power OFF at the On/Off switch and unplug ac line cord from electrical outlet. Remove HOOD SHROUD ASSEMBLY. (See “How To...”) Using a torx screwdriver, remove SCREWS (4) securing the REAR STEP ASSEMBLY.
Life Fitness Model 9500 Series Cross-Trainers How To...Replace Power Module Assembly Tools Required: Torx screwdriver, Side cutter pliers, Socket Set 1. Turn power off at the ON/OFF switch and unplug ac line cord from electrical outlet. 2. Remove the HOOD SHROUD ASSEMBLY (See “How To...”).
Life Fitness Model 9500HR Cross-Trainer How To... Replace Crank Shaft Pulley Assembly Tools required: Hex Key Set, Open End Wrench, Socket Set, Flat Blade and Phillips screwdriver, Torxdriver WARNING: FAILURE TO OBSERVE SAFE PROCEDURES WHEN SERVICING THIS UNIT COULD RESULT IN INJURY AND OR ELECTRICAL SHOCK 1.
Life Fitness Model 9500 Series Cross-Trainers How To... Replace Intermediate Pulley Assembly Tools required: Hex Key Set, Open End Wrench, Socket Set, Flat Blade and Phillips screwdriver, Torxdriver WARNING: FAILURE TO OBSERVE SAFE PROCEDURES WHEN SERVICING THIS UNIT COULD RESULT IN INJURY AND OR ELECTRICAL SHOCK 1.
Life Fitness Model 9500 Series Cross-Trainers ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD (Equipped with DSP Heart Rate PCB) Functional Description Connector P5 The Display Console Board is designed to work in conjunction with the Alternator Control Board. It reads the...
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Life Fitness Model 9500 Series Cross-Trainers ELECTRONICS OVERVIEW – DISPLAY CONSOLE (Equipped with DSP Heart Rate PCB) Connector Location Functional Description P5 is an 8 pin connector that HR-ENABLE (3.8 VDC) connects the Life Pulse Board to the Console Board. Equipped for VSYS (7-8 VDC) LC9500HR only.
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Life Fitness Model 9500 Series Cross-Trainers ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD (Equipped with Integrated PCB) Functional Description P9 and P10 The Display Console Board is designed to work in conjunction with the Alternator Control Board. It reads the keypad input for...
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Life Fitness Model 9500 Series Cross-Trainers ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD (Equipped with Integrated PCB) Connector Location Functional Description Life Pulse Right + Right - Left - Left + P9 and P10 are 8 pin N/U - not used...
Life Fitness Model 9500 Series Cross-Trainers ELECTRONICS OVERVIEW - ALTERNATOR CONTROL BOARD WARNING: RISK OF FIRE,REPLACE FUSE AS MARKED. Functional Description LIFE FITNESS A080-92167-A000 1997 The Alternator Control Board is PIN_PADSTACK designed to regulate the alternator voltage by modulating the field current.
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Life Fitness Model 9500 Series 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 provice the RPM signal from the AC TAP to the Alternator Control Board.
Life Fitness Model 9500 Series Cross-Trainers MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Cross-Trainer Model Identification Model 9500 Model 9500HR Serial Number Location Life Fitness Model 9500 Series Cross-Trainers Serial Number...
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Life Fitness Model 9500HR Cross-Trainer GK53-00012-XXXX Serial Number 669724 - UP Reading Rack Console Assembly SK53-00086-0000 SK53-00039-0001(R) Eng/Met AK53-00039-0002(R) Eng/Eng Instruction Decall AK53-00039-0003(R) Ger/Met OK53-01133-0001(Eng) AK53-00039-0004(R) Spn/Eur OK53-01133-0003(Ger) AK53-00039-0005(R) Spn/Eng OK53-01133-0004(Spn) Overlay Bezel AK53-00039-0006(R) Jap/Met OK53-01133-0006(Jap) SK53-00040-0001 Eng/Eng/Met AK53-00039-0007(R) Frn/Eur...
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Life Fitness Model 9500HR Cross-Trainer GK53-00012-XXXX Serial Number 669724 - UP...
Life Fitness Model 9500 Series Cross-Trainers PREVENTIVE MAINTENANCE TIPS ITEM WEEKLY MONTHLY QUARTERLY BI-ANNUAL ANNUAL Shrouds Wipe Clean Stop Switch Inspect For Proper Operation Power Control Board Vacuum Drive Belt Inspect and Retension Power Cord Inspect For Excessive Wear Display Console...
Life Fitness Model 9500 Series Cross-Trainers UNPACKAGING INSTRUCTIONS 1. Remove all staples from the corrugated shipping container and fold down the four sides of the base tray (A). 2. Lift and open the top flaps of the shipping container sleeve (B). Lift and remove the four corner posts (C). Lift and remove the top support (D) and the side supports (E).
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.
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CUSTOMER SUPPORT SERVICES PARTS ORDER SALE ( IF BOTH PLEASE INDICATE ) PRODUCT TROUBLESHOOTING WARRANTY NAME: CUSTOMER NO: DATE: PHONE: FAX: CONTACT NAME: METHOD OF SHIPMENT: 1 DAY 2 DAY GROUND PARTS ORDER FORM ITEM NO. PART NUMBER DESCRIPTION QUANTITY PRODUCT TROUBLESHOOTING PRODUCT NAME: SERIAL NO.