Life Fitness LS 9100 Service Manual Download Page 53

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Life Fitness 9100/9500HR Belt Drive Stairclimbers

How To

…

REMOVE AND REPLACE THE POWER CONTROL BOARD

Tools Required:

Thermal compound, Phillips screwdriver, and 5/32” Allen head wrench

Step 1

Turn the power OFF. Disconnect the power cord from the outlet.

Step 2

Remove the HOUSING. (See “How To...”)

Step 3

Locate the POWER BOARD. Disconnect the POWER BOARD CONNECTORS

Step 4

With a phillips screwdriver, remove the (4) POWER BOARD SCREWS and the worn POWER BOARD.

Step 5

Reverse steps 1 through 4 to return all parts to their proper position.

Power Control Board

Bearing Plate

Torque Screws
to 35 in. lbs.

Summary of Contents for LS 9100

Page 1: ...Life Fitness 9100 9500HR Belt Drive Series Stairclimbers CUSTOMER SUPPORT SERVICES SERVICE MANUAL LS 9100 LS 9500HR...

Page 2: ...ith 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...

Page 3: ...This field current along with the energy supplied by the user is sent to the Load Resistors This places resistance on the rotation thus providing the load sensation felt by the user The Alternator al...

Page 4: ...PLACE HOLDER FOR BLANK PAGE BACK OF INTRODUCTION PAGE...

Page 5: ...oad During Program 9 Inaccurate Count Of Steps Goal Or Actual 10 Excessive Resistance Varies During Program 11 Resistance Varies During Program 12 Display Has No RPM 13 No Heart Rate or Display Readou...

Page 6: ...iver 23 Digital Heart Rate Sensors 9500HR Only 24 Digital Heart Rate PC Board 26 SECTION IV PAGE PARTS IDENTIFICATION AND WIRING BLOCK DIAGRAMS LS9100 GK24 00021 0100 SN 216142 UP 2 LS9500HR GK24 0002...

Page 7: ...cycle are registered trademarks of Brunswick Corporation Lifepulse Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation Any use of these trademarks without the express wri...

Page 8: ...1 Life Fitness 9100 9500HR Belt Drive Stairclimbers SECTION I TROUBLESHOOTING GUIDES...

Page 9: ...Action Handlebar grips loosening Excessive wear or damage to grip Replace Lifepulse Handle Assembly Lifepulse sensor molding loose Cleaning solution used containing acid or ammonia Replace Lifepulse...

Page 10: ...ce worn pulley Alternator For noise or vibration in the bearing shaft relieve tension on the alternator belt Spin flywheel and inspect Replace Alternator Slipping Cross over belt Inspect belt for crac...

Page 11: ...worn or damaged wire harness Faulty Display Console Using a voltmeter verify power at the cable and Display Console connection See wiring diagram for pin location Replace Display if proper voltage is...

Page 12: ...ion Manual for program availability Keypad is cold Massage keypad with fingertips Perform keypad test Refer to diagnostic mode Worn faceplate overlay Replace faulty faceplate overlay Display console V...

Page 13: ...e Using an ohmmeter verify continuity of wire harness Replace worn or damaged wire harness Display Console Using a voltmeter verify power at the cable and Display Console connection See wiring diagram...

Page 14: ...e connections or wire connectors not seated properly Disconnect then reconnect harness connections at the Display Console See How To Remove Display Console Disconnect then reconnect all connections Se...

Page 15: ...g diagram Alternator Brushes Perform alternator step height test Resistance and load will increase as the field duty cycle percent increases Perform step alternator test Tension should increase as INC...

Page 16: ...st Tension should increase as INCREASE key is pressed If tension does not increase inspect alternator brushes Brushes should not be cracked or less than 1 4 inch long Brushes should be of approximatel...

Page 17: ...ernator Brushes Perform step alternator test Tension should increase as INCREASE key is pressed If tension does not increase inspect alternator brushes Brushes should not be cracked or less than 1 4 i...

Page 18: ...form step alternator test Tension should increase as INCREASE key is pressed If tension does not increase inspect alternator brushes Brushes should not be cracked or less than 1 4 inch long Brushes sh...

Page 19: ...tions at Display Console Alternator brushes Perform step alternator test Tension should increase as INCREASE key is pressed If tension does not increase inspect alternator brushes Brushes should not b...

Page 20: ...ic mode Verify proper contact on wire harness Disconnect and connect cables See How To Remove Display and Shroud Assembly Using an ohmmeter verify continuity See wiring diagram for RPM pin location Re...

Page 21: ...andlebar Verify Lifepulse that handlebars are functioning See diagnostic Using an ohmmeter verify continuity between Lifepulse sensor and cable connection See wiring diagram Replace handlebar assembly...

Page 22: ...nge Move within three feet 1 meter of receiver Faulty receiver Replace receiver Faulty chest strap Replace chest strap Bad connection between receiver and display Inspect HR cable Check HR in diagnost...

Page 23: ...16 Life Fitness 9100 9500HR Belt Drive Stairclimbers NOTES...

Page 24: ...Life Fitness 9100 9500HR Belt Drive Stairclimbers 1 SECTION II DIAGNOSTIC MODE...

Page 25: ...Life Fitness 9100 9500HR Belt Drive Stairclimbers 2 DIAGNOSTIC MODE Large Display ACCESS AND EXECUTION...

Page 26: ...the LED matrix Program Profile Screen 7 segment LED displays and the VF display NOTE The Watts Total Cal Hill Random Manual Fat Burn and Cardio Heart Rate enunciate or LED s will remain lit and unaff...

Page 27: ...h the left most digit of the FLOORS PER MINUTE ACTUAL display and scrolling to the right across this display and through the CAL HR display The same will then be repeated for the FLOORS PER MINUTE GOA...

Page 28: ...The unit will remain in this mode indefinitely as long as the alternator RPM is greater than 0 e The initial alternator duty cycle load is factory set to 10 To increase or decrease the load settings a...

Page 29: ...that option will toggle to the alternate state and resulting option will be displayed on the VF display d Only the first option Program Limits the user can modify The remaining five options are set at...

Page 30: ...right CALORIE display window c If the units non volatile memory chip has failed or missing the values displayed a b will reflect machine usage since the last time the unit lost power and the VF messag...

Page 31: ...ntinue until all available pages have been used c Only two EEROM chip failures are currently identified EEROM FAILURE 1 EEROM memory chip data cannot be read on unit power up EEROM FAILURE 2 All pages...

Page 32: ...isplay center The time lapsed during each heart rate measurement attempt appears in the TIME window The gain required to monitor the hearts signal appears in the CALORIE window A heart shaped pattern...

Page 33: ...NOSTIC MODE Small Display ACCESS AND EXECUTION LS 9500HR LS 9100T To access diagnostics press and hold the numeric FIVE key while pressing the CLEAR PAUSE key twice To access diagnostics press and hol...

Page 34: ...ection Diagnostic State 12 Photoshoot Diagnostic State 1 LED s Keypad Test To access Diagnostic state 1 9500HRT press and hold down the number 5 key while pressing the Clear Pause key twice All the LE...

Page 35: ...arrow key to decrease resistance or the UP arrow key to increase To adjust in increments of ten LS 9500HR ONLY press the number 4 key to decrease the resistance or the number 6 to increase Press the S...

Page 36: ...Enter key to scroll forward to Diagnostic State 7 or press the Clear Pause key to scroll backwards to Diagnostic State 5 Diagnostic State 7 English or Metric Units To select English default setting or...

Page 37: ...9 Diagnostic State 11 Model Selection The Model selection mode allows you to select either an LS9500 or LS 9100 To select an LS9500 press the Up arrow key and to select an LS 9100 press the Down arrow...

Page 38: ...Life Fitness 9100 9500HR Belt Drive Stairclimbers 15 NOTES...

Page 39: ...1 Life Fitness 9100 9500HR Belt Drive Stairclimbers SECTION III How To SERVICE AND REPAIR GUIDES...

Page 40: ...2 WASHERS from the DISPLAY CONSOLE BRACKET Use a center punch and light hammer to tap out the 2 CARRIAGE BOLTS Step 4 With a 5 32 hex key wrench loosen and remove the 2 SCREWS which attach the BOOT to...

Page 41: ...TOR LOCK NUT counter clockwise while holding the ALTERNATOR PIVOT BOLT in place Remove the BOLT Step 5 With a 1 2 wrench remove the ALTERNATOR ADJUSTMENT BOLT and WASHERS 2 Step 6 Cup your right hand...

Page 42: ...to the top of the right BEARING BRACKET Step 7 Remove the retainer bracket off the right Termination Sprocket Step 8 Remove Termination Sprocket and lay the belt aside Step 9 With an E ring tool remov...

Page 43: ...To REMOVE AND REPLACE DRIVE BELT Cross Plate and Screws 6 Torque 30 in lbs PCB 1 5 6 2 4 3 Pillow Block Bearing Torque 55 ft lbs Termination Sprocket Bolt Torque 15 20 ft lbs Bracket E Ring Torque 15...

Page 44: ...bolts and remove the retainers brackets from each side Step 5 Carefully slide belt off of the clutch assemblies through the pedal arm and the lower pulleys to remove Step 6 Reverse steps 1 through 7...

Page 45: ...access to the following screws with a 7 32 hex key wrench loosen and remove the SCREWS 4 which secure the COLUMN to the FRAME Lift and remove the COLUMN with the attached BOOT NOTE Tuck the connector...

Page 46: ...of the new COLUMN Step 8 While still holding the new COLUMN in one hand pull the CONNECTOR up and out of the tube taking the slack out of the WIRE Set the new COLUMN angled towards the user on top of...

Page 47: ...the POWER MODULE to the FRAME NOTE The power module needs to be shifted side to side to have access to the crossover pulleys Step 5 With a 5 16 wrench loosen and remove the 2 SCREWS 2 WASHERS and 2 CR...

Page 48: ...to BRACKET Do not allow DISPLAY CONSOLE to fall NOTE Upon replacement tighten screws in diagonal X pattern Do not excessively tighten screws Incorrect tightening may damage console housing Non models...

Page 49: ...tangle Heart Rate telemetry 9500HRT 9100T 15 pin Rectangle Lifecenter SMALL DISPLAY Model Connector Use 9500HRT 9100T 5 pin Flat rectangle Telemetry 9500HRT 9100T 4 pin Large Square Lifepulse 9500HRT...

Page 50: ...ith a 1 4 hex key wrench remove the 4 FOOT PAD SCREWS and 4 LOCK WASHERS from the worn FOOT PAD Step 2 Lift the worn FOOT PAD up and off the LEVER Replace with new FOOT PAD Step 3 With a 1 4 hex key w...

Page 51: ...move the 2 SCREWS from the Front TRAY Guide the Front TRAY forward and down from the HOUSING With a 5 32 allen head wrench loosen and remove THE 5 32 HOUSING 4 SCREWS from the HOUSING Step 5 Guide the...

Page 52: ...h and a light hammer to tap out the 2 CARRIAGE BOLTS Step 4 With a phillips screwdriver remove the 2 MOLDED HANDLE ASSEMBLY SCREWS from the MOLDED HANDLE ASSEMBLY Pull the worn MOLDED HANDLE ASSEMBLY...

Page 53: ...n the power OFF Disconnect the power cord from the outlet Step 2 Remove the HOUSING See How To Step 3 Locate the POWER BOARD Disconnect the POWER BOARD CONNECTORS Step 4 With a phillips screwdriver re...

Page 54: ...ing to J4 on the POWER BOARD Unclip this WIRE HARNESS along the height of the FRAME Step 4 With a 5 16 wrench loosen and remove the GROUND TERMINAL NUT which attaches the GROUNDING STRAP to the ALTERN...

Page 55: ...9500HR Belt Drive Stairclimbers How To REMOVE AND REPLACE POWER MODULE continued AC Tap Pink Output Red Ground Black Field Return Purple Field Excitation Orange White Power Module 5 16 Screw 4 Torque...

Page 56: ...er cord from the outlet Step 2 Remove the HOUSING See How To Step 3 Prop up the pedal arms to relieve the tension on the belt Step 4 Using a 3 4 inch wrench loosen the lock nut on the alternator pivot...

Page 57: ...12 Remove the clutch assemblies Note the directional arrow on the face of each clutch Note the large and small trust washers the large trust washer goes behind the clutch assembly while the small thru...

Page 58: ...LOWER SPRING Step 4 With a 5 32 allen head wrench hold the LOWER SPRING SCREW in place while turning the LOWER SPRING NUT with a 3 8 open end wrench Remove the LOWER SPRING NUT and WASHER Remove the...

Page 59: ...old the UPPER SPRING SCREW in place while turning the UPPER SPRING NUT with a 7 16 open end wrench Remove the UPPER SPRING NUT and 2 WASHERS Pull the worn UPPER SPRING from the FRAME Step 5 Insert the...

Page 60: ...AL SUPPORTS Step 3 Remove 2 BOLTS WASHERS and NUTS securing HANDLEBAR LIFEPULSE SENSOR ASSEMBLY and DISPLAY CONSOLE BRACKET and remove assembly and bracket Step 4 To replace reverse order of removal N...

Page 61: ...ber Step 2 Remove 2 SCREWS and COVER from underside of HANDLEBAR LIFEPULSE SENSOR ASSEMBLY TELEMETRY RECEIVER within foam insulator is accessible Step 3 Disconnect TELEMETRY RECEIVER from WIRE HARNESS...

Page 62: ...F SENSORS PROVIDED IN THE KIT Removing the existing Lifepulse digital heart rate sensors Step 1 Using a standard flat screwdriver pry off the stainless steel sensor furthest away from you as if you we...

Page 63: ...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 finger...

Page 64: ...surface Step 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 eg the met...

Page 65: ...27 Life Fitness 9100 9500HR Belt Drive Stairclimbers NOTES...

Page 66: ...28 Life Fitness 9100 9500HR Belt Drive Stairclimbers NOTES...

Page 67: ...1 Life Fitness 9100 9500HR Belt Drive Stairclimbers SECTION IV PARTS IDENTIFICATION AND WIRING BLOCK DIAGRAMS SECTION IV...

Page 68: ...277 0009 Dut Met Overlay Bezel AK24 00251 0001 Eng Eng Met AK24 00251 0002 Ger Met AK24 00251 0004 Frn Met AK24 00251 0005 Spn Met AK24 00251 0006 Itl Met AK24 00251 0007 Jap Met AK24 00251 0009 Dut M...

Page 69: ...t Pulley Assembly AK24 00037 0003 Wheel 2 OK24 01331 0000 Leg Leveler 2 0017 00009 0835 W W Drive Belt OK24 02094 0000 Belt Retainer OK24 02041 00000 Retainer Bolts 0017 00101 1206 Pulley w Bearing OK...

Page 70: ...Drive Stairclimbers PARTS IDENTIFICATION LS 9100B STAIRCLIMBERS GK24 00021 XXXX SN 216142 UP Resistor Assembly AK24 00112 0000 Backside Idler OK35 01164 0000 Pulley w Bushing 2 OK24 02082 0000 Clutch...

Page 71: ...24 00253 0002 Ger Met AK24 00253 0004 Frn Met AK24 00253 0005 Spn Eur Met AK24 00253 0006 Itl Met AK24 00253 0007 Jap Met AK24 00253 0009 Dut Met Shroud w Decal AK24 00273 0001 Driptray AK24 00048 000...

Page 72: ...wer Module 120v 60Hz AK24 00234 0001 240v 50Hz AK24 00076 0008 220v 60Hz AK24 00076 0011 100v 50Hz AK24 00234 0002 Lower Spring 2 OK24 01715 0000 Clutch Shaft Pulley Assembly AK24 00274 0000 Belt Reta...

Page 73: ...tairclimbers PARTS IDENTIFICATION LS 9500HR STAIRCLIMBERS GK24 00022 XXXX SN 146749 148124 SECTION IV Resistor Assembly AK24 00112 0000 Backside Idler OK35 01164 0000 Pulley w Bushing 2 OK24 02082 000...

Page 74: ...281 0002 Ger Met AK24 00281 0004 Frn Eur Met AK24 00281 0005 Spn Eur Met AK24 00281 0006 Itl Met AK24 00281 0007 Jap Met AK24 00281 0009 Dut Met Shroud w Decal AK24 00273 0001 Driptray AK24 00048 0001...

Page 75: ...2 Power Module SK24 00234 0001 120v 60Hz AK24 00076 0008 240v 60Hz AK24 00076 0007 240v 50Hz AK24 00234 0002 100v 50Hz Lower Spring 2 OK24 01715 0000 Clutch Shaft Pulley Assembly AK24 00274 0000 Wheel...

Page 76: ...t Drive Stairclimbers PARTS IDENTIFICATION LS 9500HR STAIRCLIMBERS GK24 00023 XXXX SN 148125 UP Resistor Assembly AK24 00112 0000 Backside Idler OK35 01164 0000 Clutch Shaft Assembly AK24 00274 0000 P...

Page 77: ...Bezel AK24 00291 0001 Eng Met AK24 00291 0002 Ger Met AK24 00291 0004 Frn Met AK24 00291 0005 Spn Met AK24 00291 0006 Itl Met AK24 00291 0007 Jap Met AK24 00291 0009 Dut Met Shroud w Decal AK24 00273...

Page 78: ...24 00152 0002 100v 50Hz AK24 00152 0007 220v 50Hz AK24 00152 0008 240 AK24 00152 0011 200v 50Hz AK24 00152 0012 220v 60Hz Lower Spring 2 OK24 01715 0000 Clutch Shaft Pulley Assembly AK24 00274 0000 Wh...

Page 79: ...ve Stairclimbers PARTS IDENTIFICATION LS 9100T STAIRCLIMBERS GK24 00025 XXXX SN 218304 UP SECTION IV Resistor Assembly AK24 00112 0000 Backside Idler OK35 01164 0000 Clutch Shaft Assembly AK24 00274 0...

Page 80: ...0281 0002 Ger Met AK24 00281 0004 Frn Eur Met AK24 00281 0005 Spn Eur Met AK24 00281 0006 Itl Met AK24 00281 0007 Jap Met AK24 00281 0009 Dut Met Shroud w Decal AK24 00273 0001 Driptray AK24 00048 000...

Page 81: ...02 Power Module SK24 00234 0001 120v 60Hz AK24 00076 0008 240v 60Hz AK24 00076 0007 240v 50Hz AK24 00234 0002 100v 50Hz Lower Spring 2 OK24 01715 0000 Clutch Shaft Pulley Assembly AK24 00274 0000 Whee...

Page 82: ...t Drive Stairclimbers PARTS IDENTIFICATION LS 9500HR STAIRCLIMBERS GK24 00027 XXXX SN 151142 UP Resistor Assembly AK24 00112 0000 Backside Idler OK35 01164 0000 Clutch Shaft Assembly AK24 00274 0000 P...

Page 83: ...17 Life Fitness 9100 9500HR Belt Drive Stairclimbers WIRING BLOCK DIAGRAM LS9500HR SECTION IV...

Page 84: ...18 Life Fitness 9100 9500HR Belt Drive Stairclimbers WIRING BLOCK DIAGRAM LS9500HR...

Page 85: ...19 Life Fitness 9100 9500HR Belt Drive Stairclimbers WIRING BLOCK DIAGRAM LS9100T SECTION IV...

Page 86: ...20 Life Fitness 9100 9500HR Belt Drive Stairclimbers NOTES...

Page 87: ...1 Life Fitness 9100 9500HR Belt Drive Stairclimbers SECTION V MISCELLANEOUS INFORMATION...

Page 88: ...2 Life Fitness 9100 9500HR Belt Drive Stairclimbers MISCELLANEOUS INFORMATION MODEL AND SERIAL NUMBERS LOCATIONS Serial Number...

Page 89: ...MONTHLY BI MONTHLY ANNUALLY HOUSING Inside CLEAN Outside CLEAN POWER CONTROL BOARD CLEAN Heatsink CLEAN Connectors INSPECT DRIVE BELT INSPECT ALTERNATOR BELT INSPECT CLUTCHES INSPECT FOOTPADS CLEAN I...

Page 90: ...MATION Cont COMMUNICATING BY TELEFACSIMILE For parts order submittal or assistance in troubleshooting a Telefacsimile order claim form is given on the following page Copy form and complete information...

Page 91: ...O DATE PHONE FAX CONTACT NAME METHOD OF SHIPMENT 1 DAY 2 DAY GROUND PARTS ORDER FORM ITEM NO PART NUMBER DESCRIPTION QUANTITY 1 2 3 4 5 6 PRODUCT TROUBLESHOOTING PRODUCT NAME SERIAL NO DETAILED DESCRI...

Page 92: ...6 SECTION V CUSTOMER SUPPORT SERVICES 10601 W Belmont Ave Franklin Park IL 60131 PHONE 800 351 3737 Toll Free or 847 451 0036 FAX 800 216 8893 Toll Free or 847 288 3702...

Page 93: ...7 Life Fitness 9100 9500HR Belt Drive Stairclimbers NOTES...

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