Life Fitness Lifecycle upright 9500HR, Service Manual

Page 1: ...Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes Customer Support Services SERVICE MANUAL ...

Page 2: ... to trouble shooting guides and diagnostic mode to isolate cause When applicable guides are listed by problem symptom followed with suggestions of probable cause s Once source of problem is identified consult How To guides for recommended repair procedures How To sub sections are organized by replaceable part or assembly name For convenience sub section lists recommended Tools Required to complete...

Page 3: ...am Fit Test level 1 through 20 resistance almost 25 easier than the level 1 found on earlier editions of the classic Lifecycle exercise bike and much more challenging for the experienced rider Also a seat adjustment which allows a wider range of selection to accommodate most anyone The ability to select a program to match your particular needs is what distinguishes Lifecycle bikes as the world s m...

Page 4: ...ER DIAGNOSTIC MODES 3 DIAGNOSTICS STATE 1 ALL LEDS and KEYPAD TEST 4 DIAGNOSTICS STATE 2 INDIVIDUAL LED TEST 5 DIAGNOSTICS STATE 3 VERSION RPM HR and LOAD TESTS 6 DIAGNOSTICS STATE 3 VERSION RPM NETWORK STATUS and LOAD TESTS Integrated PCB Only 7 DIAGNOSTICS STATE 4 LIFEPULSE and NETWORK STATUS TESTS 8 DIAGNOSTICS STATE 4 LIFEPULSE TESTS Integrated PCB Only 9 DIAGNOSTICS STATE 5 LOOPBACK TEST 10 D...

Page 5: ...ETRY RECEIVER 28 SEAT PAD AND HANDLEBAR ASSEMBLY 29 LOCKING RACK 30 ACCESSORY TRAY 31 NOTES 32 SECTION IV ELECTRONICS OVERVIEW LC9100 AND LC9500HR DISPLAY CONSOLE BOARD DSP Heart Rate 2 LC9100 AND LC9500HR DISPLAY CONSOLE BOARD Integrated PCB Only 4 LC9100 ALTERNATOR CONTROL BOARD 6 LC9500HR ALTERNATOR CONTROL BOARD 7 ALTERNATOR 8 WIRING BLOCK DIAGRAM LC9100 9 WIRING BLOCK DIAGRAM LC9500HR Integra...

Page 6: ...ess is a registered trademark of Brunswick Corporation Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation Any use of these trademarks without the express written consent of Brunswick Corporation is forbidden M051 00K51 D008 4 01 ...

Page 7: ...1 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes SECTION I TROUBLESHOOTING GUIDES Section I ...

Page 8: ...ry Malfunctioning Display Console Test with known good Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board ACB Test with known good ACB Replace malfunctioning ACB Malfunctioning Alternator Test with known good Alternator Replace malfunctioning Alternator Display Console initializes then fails Loose connections at the alternator Power Control Board PCB and...

Page 9: ...sole Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with known good Alternator Control Board Replace malfunctioning board Malfunctioning Alternator Test Alternator output or test with known good Alternator Replace malfunctioning Alternator Display Console LEDs remain illuminated Malfunctioning Display Console Inspect for damage or depression at START key Test w...

Page 10: ...ay Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with known good ACB Replace defective Alternator Control Board Malfunctioning Alternator Test Alternator output or test with known good Alternator Replace malfunctioning Alternator Display Console keys except START key do not function Attempting to enter program not available Refer to Operation Manual fo...

Page 11: ...ning board Malfunctioning Alternator Test Alternator output or test with known good Alternator Replace malfunctioning Alternator Excessive resistance load during program Pedaling too slowly Pedal faster than 45 RPM Loose connections at the alternator Power Control Board PCB and or at the Alternator Terminals Damaged wiring harness Make sure that all connections are secure Remove connectors at the ...

Page 12: ...tor output or test with known good Alternator Replace malfunctioning Alternator Defective load resistor Test with known good resistor Replace defective resistor Resistance is constant during random or hill programs Loose connections at the alternator Power Control Board PCB and or at the Alternator Terminals Damaged wiring harness Make sure that all connections are secure Remove connectors at the ...

Page 13: ...aster than 45 RPM Loose connections at the alternator Power Control Board PCB and or at the Alternator Terminals Damaged wiring harness Make sure that all connections are secure Remove connectors at the PCB then reconnect and at the alternator terminals make sure terminal nuts are tight Inspect wiring harness for damage Replace as necessary Malfunctioning Display Console Test with known good Displ...

Page 14: ...h known good Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with known good Alternator Control Board Replace defective board Defective or damaged main wire harness Inspect Main wire harness and replace if necessary Exercise bike not stable Stabilizer foot pads Adjust Foot Pads Floor surface not level Position bike on level surface Stabilizer bar...

Page 15: ...r Belt worn Replace Belt Malfunctioning Alternator While operating the unit listen for excessive noise from Alternator Replace Alternator as necessary Free wheel Pulley not rotating freely Inspect Pulley and replace pulley as necessary Seat wobbles Seat rollers out of adjustment or excessively worn Inspect adjust or replace worn rollers as necessary Alternator voltage test Malfunctioning Alternato...

Page 16: ...Display Console Secure connection If necessary replace malfunctioning Handlebar Lifepulse Grip Assembly Heart rate DSP Board Verify that the heart rate DSP board is communicating and replace if necessary Malfunctioning Display Console Test with known good Display Console Replace malfunctioning Display Console Handlebar Lifepulse grips loose Excessive wear or damage to grip Replace the handlebar as...

Page 17: ...11 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes NOTES Section I ...

Page 18: ...1 Lifecycle 9500 9100 Series Recumbent Exercise Bikes SECTION II DIAGNOSTICS Section II ...

Page 19: ...2 Lifecycle 9500 9100 Series Recumbent Exercise Bikes Display Console Layout Message Center Profile Window Numeric Keypad Arrow Keys Message Center Profile Window L 9500 C L 9100 C ...

Page 20: ...ES LC9500 While pedaling the bike over 45 RPMs diagnostics can be entered by holding the 5 key or the down ARROW key and pressing the START key LC9100 While pedaling the bike over 45 RPMs diagnostics can be entered by holding the DOWN ARROW key and pressing the START key Section II ...

Page 21: ...ll of the LEDs will turn on Pressing keys will result in a beep sound and for all but the START ENTER and CLEAR PAUSE keys a character repeated across the message center display KEYS DISPLAYED CHARACTER 0 0 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 DISPLAY LOCK L RACE MODE R WATTS METS MODE W UP U DOWN D Press the CLEAR PAUSE key to abort DIAGNOSTICS and return to the PRESS START TO BEGIN state Press th...

Page 22: ... TEST On entry to this state the individual LEDs and display segments will be tested Indicator LEDs message center segments and profile LEDs will all animate independently Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 1 Press the START ENTER key to advance to DIAGNOSTICS STATE 3 Section II ...

Page 23: ...rom 0 415 for 9V battery products 0 250 for all others in order of increasing load This value can be adjusted using the UP DOWN keys to decrement and increment the LOAD duty cycle Pressing the DISPLAY LOCK key will disable the LOAD DUTY CYCLE display if enabled turn off the CALORIES HR and display the LIFEPULSE GAIN if HANDS ON LIFEPULSE sensors Pressing the DISPLAY LOCK key again will re enable t...

Page 24: ... be displayed in the CALORIES HOUR window LOAD DUTY CYCLE ranges from 0 415 for 9V battery products 0 250 for all others in order of increasing load This value can be adjusted using the UP DOWN arrow keys to increase or decrease the LOAD duty cycle The LOAD DUTY CYCLE can also be adjusted down or up in units of 25 using the 4 and 6 keys Pressing the WATTS METS key will toggle the display of the Li...

Page 25: ...rd DSP software ex P3 80 if present will be displayed in the HEART RATE window The status of the LIFELINK board and LIFE CENTER connection will be displayed in the CALORIES HOUR window The following conditions will be reported 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 PAUSE key to ...

Page 26: ...rmally need to be adjusted After these messages are done displaying the LifePulse test information comes up With both hands placed on the LifePulse sensors the ELAPSED TIME begins counting in the TIME window This counter will stop counting as soon as a heart rate is displayed The GAIN is displayed in the RPM window The CONFIDENCE LEVEL between 0 9 is displayed in the CALORIES HOUR window with 0 in...

Page 27: ...RS232 port is tested A shorting jumper must be connected for the result of this test to be correct If functioning correctly RS232 PASS will be displayed If not functioning correctly RS232 OFF will be displayed Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 4 Press the START ENTER key to advance to DIAGNOSTICS STATE 6 ...

Page 28: ...ned ON or OFF The UP and DOWN arrow keys toggle between CVA ENABLED and CVA DISABLED The ENTER key LED will indicated when the value is at the default setting of CVA DISABLED This value is stored in EEROM and is kept when the LifeCycle is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 4 Press the START ENTER key to advance to DIAGNOSTICS STATE 6 Section II ...

Page 29: ...y will Auto Repeat if held The UP ARROW will increase the value by 1 minute The key will Auto Repeat if held The ENTER key LED indicates when the value is at the default of 60 minutes This value is stored in EEROM and is kept when the unit is not in use To RESET the configuration items in the EEPROM to their default settings hold the DISPLAY LOCK key down while pressing the ENTER key Press the CLE...

Page 30: ...try pulse is received By default the LifeCycles will have TELEMETRY ON The DOWN ARROW will turn off the telemetry The UP ARROW will turn on the telemetry and display a heart shape in the program profile window The ENTER key LED indicates when the value is at the default setting of TELEMETRY ON This value is stored in EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return...

Page 31: ...ts 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 EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 7 Press the START ENTER key to advance to DIAGNOSTICS STATE 9 ...

Page 32: ...Cycle can be selected The DOWN ARROW will configure as a Recumbent The UP ARROW will configure as a Upright The ENTER key LED indicates when the value is at the default setting of UPRIGHT This value is stored in EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 8 Press the START ENTER key to advance to DIAGNOSTICS STATE 10 Section II ...

Page 33: ...eCycle will have the WATTS PROGRAM ON The DOWN ARROW will turn OFF the WATTS PROGRAM The UP ARROW will turn ON the WATTS PROGRAM The ENTER key LED indicates when the value is at the default setting of WATTS PROGRAM ON The value is stored in EEROM and is kept when the bike is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 9 Press the START ENTER key to advance to DIAGNOSTICS ST...

Page 34: ... METS PROGRAM ON The DOWN ARROW will turn OFF the WATTS PROGRAM The UP ARROW will turn ON the WATTS PROGRAM The ENTER key LED indicates when the value is at the default of METS PROGRAM ON This value is stored in EEROM and is kept when the bike is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 10 Press the START ENTER key to advance to DIAGNOSTICS STATE 12 METS P R O G R A M ON...

Page 35: ...l scroll through the selections of 6 VOLT BATTERY EXTERNAL SUPPLY or 9 VOLT BATTERY NOTE LC9100 uses a 9 volt battery LC9500 uses a 6 volt battery The ENTER key LED indicates when the value is the default of 6V battery This value is stored in EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 11 Press the START ENTER key to advance to DIAGNOSTICS...

Page 36: ... shows the number of times each program has been selected The DOWN ARROW backs up through the list of available programs and back to the total hours displayed To clear the statistics in the EEPROM hold the DISPLAY LOCK key down while pressing the ENTER key The Programs are HOUR HILL RANDOM MANUAL FAT CARDIO FIT WATTS METS QUICK HRT HILL HRT INT HRT EXT SPRT TRN Pressing the CLEAR PAUSE key will re...

Page 37: ... as to the presence of numeric keys The DOWN ARROW will display NUMERICS OFF The UP ARROW will display NUMERICS ON The ENTER key LED indicates when the value is at the default of NUMERIC KEYS ON This value is stored in EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 13 Press the START ENTER key to advance to DIAGNOSTICS STATE 15 ...

Page 38: ...STICS STATE 15 PHOTO SHOOT This state is solely intended to be used for PHOTO SHOOTS None of the data items displayed are real Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 14 Press the START ENTER key to advance to DIAGNOSTICS STATE 16 Section II 28 45 135 82 725 ...

Page 39: ...L HEART RATE EXTREME or REAL WORLD BIKE The DOWN ARROW will display PROGRAMS OFF The UP ARROW will display PROGRAMS ON The ENTER key LED indicates when the value is set to default of PROGRAMS OFF This value is stored in EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 14 Press the START ENTER key to advance to DIAGNOSTICS STATE 16 ...

Page 40: ...talian Dutch Spanish or Portuguese The UP ARROW will display the next language in the list The DOWN ARROW will display the previous language in the list The ENTER key LED indicates when the language is set to the default of ENGLISH This value is stored in EEROM and is kept when the unit is not in use Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 15 Press the START ENTER key to advance t...

Page 41: ...sed locations in the Display Console EEPROM The EEPROM location being tested will appear in the display message center Pressing the DOWN ARROW will initiate the EEPROM test If the test completes successfully the message EEPROM GOOD will appear If the test fails the message EEPROM BAD AT XX will display with the bad EEPROM location Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 16 Press t...

Page 42: ...s DIAGNOSTICS DIAGNOSTICS STATE 18 PHOTO SHOOT Integrated PCB Only This state is solely intended to be used for PHOTO SHOOTS None of the data items displayed are real Press the CLEAR PAUSE key to return to DIAGNOSTICS STATE 17 28 45 135 82 725 Section II ...

Page 43: ...26 Lifecycle 9500 9100 Series Recumbent Exercise Bikes NOTES ...

Page 44: ...1 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes SECTION III How To SERVICE AND REPAIR GUIDES Section III ...

Page 45: ...it NOTICE If only the alternator is being replaced then remove the ALTERNATOR PULLEY 6 Install the new alternator in the reverse order Make sure that the ALTERNATOR BELT is properly aligned to the LARGE PULLEY as shown otherwise damage to the belt can occur 7 Locate the alternator at the marked area on the alternator bracket Alternator belt tension should be from 60 70 lbs Large Pulley Alternator ...

Page 46: ...he ALTERNATOR PIVOT BOLT and push the ALTERNATOR forward to slacken the ALTERNATOR BELT 4 Mark the position of the IDLER BRACKET Remove and loosen MOUNTING BOLTS as illustrated 5 Loosen the TENSION BOLT and move the IDLER BRACKET forward to slacken the POWER GRIP BELT Alternator Pivot Bolt Torque 30 35 FT LBS Alternator Belt Power Grip Belt Alternator Tensioning Bolt Torque 18 20 FT LBS Alternator...

Page 47: ...rom the unit 9 Remove the ALTERNATOR BELT 10 Install the new alternator in the reverse order Make sure that the ALTERNATOR BELT is properly aligned to the LARGE PULLEY as shown otherwise damage to the belt can occur 11 Locate the alternator at the marked area on the alternator bracket Alternator belt tension should be from 60 70 lbs and the POWER GRIP BELT from 35 55 lbs Large Pulley Alternator Be...

Page 48: ...sen the ALTERNATOR PIVOT BOLT and push the ALTERNATOR forward to slacken the ALTERNATOR BELT 4 Mark the position of the IDLER BRACKET Remove and loosen MOUNTING BOLTS as illustrated 5 Loosen the TENSION BOLT and move the IDLER BRACKET forward to slacken the POWER GRIP BELT Alternator Pivot Bolt Torque 30 35 FT LBS Alternator Belt Power Grip Belt Alternator Tensioning Bolt Torque 18 20 FT LBS Alter...

Page 49: ...Y forward and out of the bike 10 Slide the FREEWHEEL off the SHAFT noting location of washers 11 Install the new alternator in the reverse order Make sure that the ALTERNATOR BELT is properly aligned to the LARGE PULLEY as shown otherwise damage to the belt can occur 12 Locate the alternator at the marked area on the alternator bracket Alternator belt tension should be from 60 70 lbs and the POWER...

Page 50: ...he ALTERNATOR PIVOT BOLT and push the ALTERNATOR forward to slacken the ALTERNATOR BELT 4 Mark the position of the IDLER BRACKET Remove and loosen MOUNTING BOLTS as illustrated 5 Loosen the TENSION BOLT and move the IDLER BRACKET forward to slacken the POWER GRIP BELT Alternator Pivot Bolt Torque 30 35 FT LBS Alternator Belt Power Grip Belt Alternator Tensioning Bolt Torque 18 20 FT LBS Alternator...

Page 51: ...LEY ASSEMBLY forward and out of the bike and remove the POWER GRIP BELT 10 Install the new alternator in the reverse order Make sure that the ALTERNATOR BELT is properly aligned to the LARGE PULLEY as shown otherwise damage to the belt can occur 11 Locate the alternator at the marked area on the alternator bracket Alternator belt tension should be from 60 70 lbs and the POWER GRIP BELT from 35 55 ...

Page 52: ... Tools Required 5 32 inch hex key wrench 1 Disengage the LOCKING MECHANISM and slide the seat to its most forward position 2 Remove the two 5 32 inch hex key screws from the LOCKING MECHANISM 3 Remove the LOCKING MECHANISM 4 Install new LOCKING MECHANISM in reverse order Locking Mechanism Bolts Section III ...

Page 53: ... in the crank arm PULLEY remove the right BEARING RETAINER SCREWS 2 8 Remove the CRANKARM out of the bike frame from its right side 9 Remove the right crank arm BEARING NUT and slide it off the CRANKARM 10 Install new crankarm bearings in reverse order Before assembling use a clean rag to thoroughly clean out the crank arm bearing area 11 Install the RIGHT BEARING NUT assembly onto the right CRANK...

Page 54: ...t clockwise until this tab is positioned in the center of the bearing nut flat then secure it against the bearing nut flat with a hammer 15 Install the CRANK ARM NUT and hand thread counterclockwise against the TAB WASHER With the special wrench tighten to a torque of 4 FT LBS Now bend the remaining tab up against the center flat of the crank arm nut If necessary back off this nut clockwise until ...

Page 55: ... holding the retainer bracket for the FLAT FLEX CABLE and remove the grommet 4 Disengage the LOCKING MECHANISM and carefully back the SEAT ASSEMBLY off the EXTRUSION while guiding the flat flex cable out from the seat extrusion 5 If necessary to replace the EXTRUSION remove the FLAT FLEX CABLE in the EXTRUSION then remove four mounting bolts located under the ends of the EXTRUSION Replace EXTRUSIO...

Page 56: ...s in this section to remove the right SHROUD 3 For the LC9500HR only disconnect the BLACK neg wire from the post on the BATTERY then the RED pos wire from the post 4 Disconnect the MAIN WIRE HARNESS P1 at the ALTERNATOR CONTROL BOARD 5 Note the location of the CABLE TIES on frame then cut them off 6 Route the MAIN WIRE HARNESS out through the bottom FRAME TUBE and secure with new cable ties 7 Inst...

Page 57: ...nd the other to torque the ROLLER CLAMP NUT 4 Starting with the right side SEAT ROLLERS adjust the first TAKE UP ROLLER NUT to 60 65 in lbs in a clockwise direction Observe that the ROLLER CLAMP NUT will move up This indicates that the seat roller is being forced up against the extrusion Continue to maintain the 60 65 in lbs resistance load on the take up roller and secure the seat roller position...

Page 58: ...os wire from the post 3 Remove the two SCREWS securing the BATTERY to the bracket Remove the BATTERY and discard 4 Install new BATTERY and secure with the two SCREWS 5 Reconnect the BLACK neg wire to the post on the BATTERY and the RED pos wire to the post Carefully tuck the BATTERY WIRES back into the HOUSING 6 Lift the bike to its upright position and test all operations Battery Bracket 6V batte...

Page 59: ...ATTERY DOOR located on the rear of the CONSOLE 2 Disconnect the 9 VOLT ALKALINE BATTERY from the WIRE HARNESS and replace with a new 9 VOLT ALKALINE BATTERY 3 Carefully insert 9 VOLT ALKALINE BATTERY and WIRE HARNESS into the back of the display console 4 Reinstall the BATTERY DOOR and secure with SCREW 9 Volt Alkaline Battery Battery Door Screw Console Wire Harness ...

Page 60: ...E LC9500HR and TELEMETRY CABLE from the back of the DISPLAY CONSOLE 3 Remove two HEX SCREWS from the front of the HANDLE BAR COLUMN 4 Lift off the HANDLE BAR Assembly from the column while carefully guiding the wire harnesses out 5 Install the new DISPLAY CONSOLE in the reverse order Make sure not to pinch the cables or over tighten the display console mounting screws 6 Test operation of the Lifec...

Page 61: ... 2 Note the WIRE HARNESS position and disconnect the ALTERNATOR P2 and MAIN WIRE HARNESSES P1 from the ALTERNATOR CONTROL BOARD 3 Remove four mounting SCREWS securing the ALTERNATOR CONTROL BOARD to its mounting bracket 4 Install new Alternator Control Board in reverse order Alternator Control Board Alternator Control Board Mounting Bracket Alternator Wire Harness Main Wire Harness Control Board M...

Page 62: ...the worn STRAP and pull AWAY and DOWN from the knob on the PEDAL 2 Grasp the inside of the worn STRAP and pull AWAY and DOWN from the knob on the PEDAL 3 Insert the outside of the new STRAP with the slit on the outside knob of the PEDAL Pull the STRAP UP until it locks in place 4 Insert the inside of the new STRAP with the slit on the inside knob of the PEDAL Pull the STRAP UP until it locks in pl...

Page 63: ...lips screwdriver 1 Remove the SCREW and WASHER at the end of the WHEEL 2 Remove and discard WHEEL 3 Install new wheel in reverse order 4 If the wheel inserts require replacement remove the two INSERT SCREWS and slide INSERT out and replace with new INSERT Wheel Washer Screw 20 25 IN LBS Insert Insert Screws ...

Page 64: ...t away from you as if you were the user gripping the Lifepulse heart rate monitoring sensors if screw access holes are already provided in the sensor you wish to replace simply remove the two screws and continue to Step 2 This will be the sensor on which your fingertips rest during use This sensor will be referred to as the ground sensor black or green wire hereafter in these instructions The sens...

Page 65: ...sor and locate it into position This sensor will be the sensor on which the palm rests during use 5 Plug the Faston connector black or green wire to the back of the new pre assembled ground sensor assembly this will be the assembly with the screw access holes in the sensor and locate it into position This is the sensor on which the fingertips rest during use 6 Install the two screws through the ac...

Page 66: ...e flat surface 4 Ground yourself to the machine by attaching one end of a DISPOSABLE ANTI STATIC GROUNDING STRAP to your wrist and the other to a suitable grounding point on the exercise bike e g the metal part of the pedal crankshaft 5 Use the pliers to squeeze the tips of the five SPACERS one at a time to allow removal of the HEART RATE PC BOARD Before lifting the HEART RATE PC BOARD from positi...

Page 67: ...right crankarm at the 2 o clock position and guide the SHROUD up and over the crankarm 5 Inside the LEFT SHROUD remove the left shroud screw see illustration from the center of the IDLER BRACKET 6 From the outside of the LEFT SHROUD remove 4 outer screws 7 Position the left crankarm to a 10 o clock position and carefully guide the LEFT SHROUD up and over the left crankarm and pedal 8 Replace the S...

Page 68: ...ve the RIGHT PEDAL place a 5 8 inch open end wrench on the PEDAL BOLT and turn the wrench counterclockwise 3 Install the new PEDALS onto the CRANK ARMS To tighten the PEDALS place a 5 8 inch open end wrench on the PEDAL BOLT Move the wrench counterclockwise for the LEFT PEDAL and clockwise for the RIGHT PEDAL Right Pedal Counterclockwise to Remove Clockwise to Install Left Pedal Clockwise to Remov...

Page 69: ...ls Required 5 32 inch hex key wrench 1 Remove the four SCREWS from the SEAT BACK and remove the seat back 2 Position the new SEAT BACK against the SEAT FRAME and secure with four mounting SCREWS NOTE MAKE SURE THE SEAT IS PROPERLY SECURE BEFORE RIDING Seat Back Seat Frame Washers 4 Screws 4 ...

Page 70: ...ike and in front of the STABILIZER BAR 2 Remove the two STABILIZER BOLTS from the bottom of the STABILIZER BAR Remove the STABILIZER BAR from the bike frame 3 Install the new STABILIZER BAR and tighten the bolts to a torque of 200 to 220 INCH LBS Make sure the STABILIZER BAR is mounted flush against the rear frame of the bike 4 If the bike is not level turn the two LEVELERS as necessary to elimina...

Page 71: ... Phillips Screwdriver 1 Remove LABEL from front of cover 2 Remove the two SCREWS and COVER under the HANDLEBAR 3 Disconnect TELEMETRY RECEIVER from the wire cable Removing the receiver from foam insulator INSTALL NEW TELEMETRY RECEIVER IN REVERSE ORDER Cable Cover Screws 6 8 IN LBS Receiver Unit Foam Protector ...

Page 72: ...e ALLEN SCREWS to 55 60 IN LBS 4 Remove the four TORX SCREWS and WASHERS securing the HANDLEBAR ASSEMBLY to the SEAT ASSEMBLY 5 Remove the HANDLEBAR ASSEMBLY Disconnect HR CABLE LC9500HR ONLY 6 Install new HANDLEBAR ASSEMBLY and secure with TORX SCREWS and WASHERS Reconnect HR cable LC9500HR ONLY Torque TORX SCREWS to 32 34 IN LBS 7 Replace the SEAT PAD and secure with ALLEN SCREWS and WASHERS Tor...

Page 73: ...sengage LOCKING MECHANISM and slide SEAT ASSEMBLY to the rear of the EXTRUSION 2 Remove ALLEN SCREW from the front of the LOCKING RACK 3 Disengage LOCKING MECHANISM and carefulley slide SEAT ASSEMBLY to the front of the EXTRUSION 4 Remove ALLEN SCREW from the rear of the LOCKING RACK and remove LOCKING RACK 5 Replace LOCKING RACK in the reverse order of the above steps Torque Allen screws to 50 55...

Page 74: ...de the ACCESSORY TRAY D over the user right SEAT BACK POST E and down to make contact with the SEAT HANDLEBAR F 3 Position the UNDERSIDE CLAMP BRACKET G around the SEAT HANDLEBAR F and tighten the two CLAMP SCREWS and WASHERS H NOTE BE CAREFUL NOT TO OVER TIGHTEN THE SCREWS H 4 Align the four holes in the SEAT BACK B with those in the SEAT BACK POSTS Insert the four SCREWS A and WASHERS B through ...

Page 75: ...32 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes NOTES ...

Page 76: ...1 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes SECTION IV ELECTRONICS OVERVIEW AND WIRING BLOCK DIAGRAMS Section IV ...

Page 77: ...ofile display matrix Connectors and Pin Descriptions Connector Location Pin Functional Description 1 Ground 2 Strobe 3 Strobe 4 Return 5 Strobe 6 Return 7 Strobe 8 Return 9 Strobe 10 Return 11 Ground 12 Start 13 Strobe 14 Return 15 Strobe 16 Return P1 is a 17 pin ribbon connector that connects to the Overlay Board 17 Ground 1 VSYS POWER CONTROL 7 8VDC 2 RPM 0 7 5 VDC 3 GROUND 4 LOAD 5 VBAT 6 VDC 6...

Page 78: ...ocation Pin Functional Description 1 HR ENABLE 3 8 VDC 2 KEY 3 VSYS 7 8 VDC 4 VSYS 7 8 VDC 5 GROUND 6 GROUND 7 HR D0 4 5 VDC P5 is an 8 pin connector that connects the Life Pulse Board to the Console Board Equipped for LC9500HR only 8 HR D1 4 5 VDC 1 VCC 5VDC 2 POLAR SIGNAL P7 is a 3 pin connector that comes from the Polar connector 3 GROUND Section IV ...

Page 79: ...and refreshes the status LEDs data display and profile display matrix Connectors and Pin Descriptions Connector Location Pin Functional Description 1 Ground 2 Strobe 3 Return 4 Strobe 5 Strobe 6 Return 7 Strobe 8 Return 9 Strobe 10 Return 11 Ground 12 Strobe 13 Strobe 14 Return 15 Strobe 16 Return P1 is a 17 pin ribbon connector that connects to the Overlay Board 17 Ground 1 VSYS POWER CONTROL 7 8...

Page 80: ...escription 1 Right 2 Right 3 Left Heart rate connector 4 Left 1 N U not used 2 N U not used 3 Receive Data 4 Transmit Data 5 8 Vdc 6 CTS 7 Ground P9 and P10 are 8 pin connectors that connect to the CSAFE and Cardio Theater interface 8 N U not used 1 VCC 5VDC 2 POLAR SIGNAL P7 is a 3 pin connector that connects the polar receiver to the console 3 GROUND Section IV ...

Page 81: ...load resistor while providing supply voltage for the console while charging the system battery Connectors and Pin Connections Connector Location Pin Functional Description 1 RPM 0 7 5 VDC 2 VBAT 9VDC 3 NOT USED BLANK 4 LOAD 5 START 6 GROUND 7 GROUND 8 ALTREGLO 9 11 VDC P1 is a Molex 9 pin connector that connects to the Console 9 VSYS 7 8 VDC 1 FLD RTN 2 FIELD 1 4 VDC 3 VALT 10 VDC 4 LOAD 5 LOAD 6 ...

Page 82: ...ge for the console while charging the system battery Connectors and Pin Connections Connector Location Pin Functional Description 1 GROUND BLACK 2 GROUND BATTERY 3 NOT USED BLANK 4 VSYS 7 8VDC 5 ALTREGLO 9 11 VDC 6 LOADCMD 7 RPM 0 7 5VDC 8 START 7 8VDC 9 VBAT 6VDC 10 GROUND BATTERY P1 is a Molex 11 pin connector that connects to the Console 11 GROUND 1 GROUND ALTERNATOR 2 GROUND ALTERNATOR 3 GROUN...

Page 83: ...ription 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 AC TAP TERMINAL OUTPUT TERMINAL FIELD TERMINALS GROUND TERMINAL EXCITATION RETURN ...

Page 84: ... VALT 0 5 OHM 5 240 W RED 2 14 POS CON17LIF P1 P2 P1 P2 10 11 13 12 15 14 8 P6 MOLEX MINI FIT JR 8 POS 3 5 2 1 4 ORANGE BROWN RED GREEN WHITE BLACK VSYS MISO MOSI NETOFF NETSEL GND BLUE 6 SC K POLAR GND VCC MOLEX MINI FIT JR 3 POS BLACK WHITE 3 2 POLAR RECEIVER RED 1 P7 NETWORK 10 POS MOLEX MINI FIT JR P1 GND VSYS MISO NETSEL NETOFF SCK MOSI GND 8 2 5 6 7 4 3 1 P2 VDC CTS TX RX P3 1 2 3 4 5 6 7 8 ...

Page 85: ...HM 5 240 W RED 2 12 POS P2 P1 P2 POLAR GND VCC MOLEX MINI FIT JR 3 POS BLACK WHITE 3 2 POLAR RECEIVER RED 1 P7 MANDO FIELD EXCITATION KOREA AC TAP MANDO ALTERNATOR NOT TO SCALE FIELD RETURN GND OUTPUT 1 4 RING TERMINALS 8 RING TERMINALS M5 RING TERMINAL M5 RING TERMINAL 8 RING TERMINAL LOAD LOAD 2 GND BLK VLT 5 VBAT GND 10 BLK VLT 10 VBAT RED RED FASTON250 FASTON187 KEY 3 N U START ENTER CLR PAUSE...

Page 86: ...OLAR RECEIVER RED 1 P7 NETWORK 10 POS MOLEX MINI FIT JR P1 GND VSYS MISO NETSEL NETOFF SCK MOSI GND 8 2 5 6 7 4 3 1 P2 VDC CTS TX RX P3 1 2 3 4 5 6 7 8 GND TX CTS VDC RX MOD PLUG 8 1 2 4 5 7 8 POS MOD PLUG 8 POS 10 MANDO FIELD EXCITATION KOREA AC TAP MANDO ALTERNATOR NOT TO SCALE FIELD RETURN GND OUTPUT OPTIONAL 1 4 RING TERMINALS 8 RING TERMINALS M5 RING TERMINAL M5 RING TERMINAL 8 RING TERMINAL ...

Page 87: ...12 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes NOTES ...

Page 88: ...1 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes SECTION V PARTS IDENTIFICATION Section V ...

Page 89: ...73 0001 R Eng Met AK51 00073 0003 Ger Met AK51 00073 0004 Spn Met AK51 00073 0007 Frn Met AK51 00073 0008 Itl Met AK51 00073 0009 Dut Met Console Post Assembly SK51 00022 0000 Grips OK14 01124 0000 Polar HR Kit SK40 00045 0001 Pedal w Strap R AK17 00026 0015 Pedal w Strap L AK17 00026 0015 Seat Bottom OK51 01054 0000 Tray Assembly SK51 00074 0000 End Cap SK51 00058 0000 End Cap Decal OK51 01048 00...

Page 90: ...51 00060 0000 Crank Arm w Pulley SK51 00024 0000 Crank Arm Pulley OK51 01009 0000 Idler Arm Bracket OK51 01022 0000 Power Grip Belt OK46 01009 0000 Idler Pulley w Bushing OK46 01008 0002 Alternator Control Board SK51 00052 0000 Timing pulley SK51 00028 0000 Alternator Pulley Assembly SK17 00106 0000 Extruded Tube Assembly SK51 00036 0000 Pulley Shaft OK51 01015 0000 Shaft Retainer OK51 01028 0000 ...

Page 91: ...027 0000 Front Stop Bracket OK51 01062 0000 Plastic Shield OK19 01185 0000 Shroud w Decal RT SK51 00059 0001 Shroud Decal RT OK51 01051 0000 Shroud Screw 11 0017 00101 0991 Wheel Assembly SK51 00054 0000 Wheel Bearing Assembly SK18 00016 0000 Wheel Inserts OK51 01017 0000 Wheel Washers OK17 01029 0000 Wheel Screw 0017 00101 1611 Insert Screw 0017 00101 1611 Shroud w Decal LT SK51 00059 0002 Shroud...

Page 92: ... Met AK49 00033 0009 Dut Met AK49 00033 0010 Frn Met Display Console AK51 00081 0001 Console Post Assembly SK51 00022 0000 Grips OK14 01124 0000 Polar HR Kit SK40 00045 0001 Pedal w Strap R AK17 00026 0015 Pedal w Strap L AK17 00026 0015 Seat Bottom OK51 01054 0000 Tray Assembly AK51 00074 0000 End Cap AK51 00084 0000 End Cap Decal 0K51 01087 0000 Stabilizer Bar SK18 00017 0000 Levelers 2 w Pads S...

Page 93: ...w Pulley AK51 00024 0000 Crank Arm Pulley SK51 01009 0000 Idler Arm Bracket OK51 01022 0000 Power Grip Belt 0K46 01009 0000 Idler Pulley w Bushing OK46 01008 0002 Alternator Control Board SK51 00051 0000 Timing pulley SK51 00028 0000 Alternator Pulley Assembly SK17 00106 0000 Extruded Tube Assembly SK51 00014 0000 Pulley Shaft OK51 01015 0000 Shaft Retainer OK51 01028 0000 Poly V Belt 0017 00009 1...

Page 94: ...ont Stop Bracket 0K51 01062 0000 Plastic Shield 0K19 01185 0000 Shroud w Decal RT AK51 00085 0001 Shroud Decal RT 0K51 01087 0000 Shroud Screw 11 0017 00101 0991 Wheel Assembly SK51 00054 0000 Wheel Bearing Assembly SK18 00016 0000 Wheel Inserts 0K51 01017 0000 Wheel Washers 0K17 01029 0000 Wheel Screw 0017 00101 1611 Insert Screw 0017 00101 1611 Shroud w Decal LT AK51 00085 0002 Shroud Decal LT O...

Page 95: ...0010 0003 Ger Met AK51 00010 0004 Spn Eur AK51 00010 0005 Spn Met AK51 00010 0006 Jap Met AK51 00010 0007 Frn Eur AK51 00010 0008 Itl Met AK51 00010 0009 Dut Met AK51 00010 0010 Frn Met Console Post Assembly SK51 00022 0000 DSP Board SK51 00071 0000 Grips OK14 01124 0000 Polar HR Kit SK40 00045 0001 Pedal w Strap R AK17 00026 0015 Pedal w Strap L AK17 00026 0015 Seat Bottom OK51 01054 0000 Tray As...

Page 96: ... Pulley SK51 01009 0000 Idler Arm Bracket OK51 01022 0000 Power Grip Belt OK46 01009 0000 Idler Pulley w Bushing OK46 01008 0002 Alternator Control Board SK51 00051 0000 Timing pulley SK51 00028 0000 Alternator Pulley Assembly SK17 00106 0000 6 Volt Battery 0017 00003 0685 Extruded Tube Assembly SK51 00014 0000 Heart Rate Electrode Kit GK20 00002 0002 Handle Bar w Inser SK19 00108 0000 Pulley Shaf...

Page 97: ...ud Bracket OK51 01027 0000 Front Stop Bracket OK51 01062 0000 Plastic Shield OK19 01185 0000 Shroud w Decal RT SK51 00015 0001 Shroud Decal RT OK51 01041 0000 Shroud Screw 11 0017 00101 0991 Wheel Assembly SK51 00054 0000 Wheel Bearing Assembly SK18 00016 0000 Wheel Inserts OK51 01017 0000 Wheel Washers OK17 01029 0000 Wheel Screw 0017 00101 1611 Insert Screw 0017 00101 1611 Shroud w Decal LT SK51...

Page 98: ... 00087 0003 Ger Met AK51 00087 0004 Spn Eur AK51 00087 0005 Spn Met AK51 00087 0006 Jap Met AK51 00087 0007 Frn Eur AK51 00087 0008 Itl Met AK51 00087 0009 Dut Met AK51 00087 0010 Frn Met Console Post Assembly SK51 00022 0000 Grips OK14 01124 0000 Polar HR Kit SK40 00045 0001 Pedal w Strap R AK17 00026 0015 Pedal w Strap L AK17 00026 0015 Seat Bottom OK51 01054 0000 Tray Assembly SK51 00072 0000 E...

Page 99: ...Pulley SK51 01009 0000 Idler Arm Bracket OK51 01022 0000 Power Grip Belt OK46 01009 0000 Idler Pulley w Bushing OK46 01008 0002 Alternator Control Board SK51 00051 0000 Timing pulley SK51 00028 0000 Alternator Pulley Assembly SK17 00106 0000 6 Volt Battery 0017 00003 0685 Extruded Tube Assembly SK51 00014 0000 Heart Rate Electrode Kit GK20 00002 0002 Handle Bar w Inser SK19 00108 0000 Pulley Shaft...

Page 100: ...K51 01027 0000 Front Stop Bracket OK51 01062 0000 Plastic Shield OK19 01185 0000 Shroud w Decal RT SK51 00015 0001 Shroud Decal RT OK51 01041 0000 Shroud Screw 11 0017 00101 0991 Wheel Assembly SK51 00054 0000 Wheel Bearing Assembly SK18 00016 0000 Wheel Inserts OK51 01017 0000 Wheel Washers OK17 01029 0000 Wheel Screw 0017 00101 1611 Insert Screw 0017 00101 1611 Shroud w Decal LT SK51 00015 0002 ...

Page 101: ...14 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes NOTES ...

Page 102: ...1 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes SECTION VI MISCELLANEOUS INFORMATION Section VI ...

Page 103: ...2 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Serial Number Location ...

Page 104: ...utside Clean ALTERNATOR CONTROL Heatsink Clean Connectors Inspect Board Inspect Belt Power Grip Inspect Crank Bearings Inspect Pedals Clean Inspect Freewheel Pulley Clean Inspect Alternator Flywheel Clean Inspect Locking Mechanism Inspect SEAT ASSEMBLY Top Surface Clean Rollers Inspect ALTERNATOR BELT Tension Inspect Wear Inspect Lifepulse sensors Clean Section VI ...

Page 105: ...isplay Console Operation Manual Installation Instructions Parts Bag Note Console assembly is not included with media platform bike Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes Unpacking Instructions IMPORTANT SAVE YOUR PACKING MATERIALS IN CASE OF RETURN ...

Page 106: ...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 Section VI ...

Page 107: ...ER FORM ITEM NO PART NUMBER DESCRIPTION QUANTITY 1 2 3 4 5 6 PRODUCT TROUBLESHOOTING PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM PRODUCT NAME SERIAL NO DETAILED DESCRIPTION OF PROBLEM TIME RECEIVED TIME COMPLETED TECHNICIAN NAME CUSTOMER SUPPORT SERVICES 10601 W Belmont Ave Franklin Park IL 60131 PHONE 800 351 3737 Toll Free or 708 451 0036 FAX 800 216 8893 Toll Free or 708 288 3702 ...

Page 108: ...7 Lifecycle 9500HR 9100 Series Recumbent Exercise Bikes NOTES Section VI ...