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LifeFitness 9500HR, Service Manual

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LifeFitness 9500HR Service Manual Download Page 6

TM

©1999 Brunswick Corporation. All rights reserved. Life Fitness and Lifecycle 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 written consent of Brunswick Corporation, is forbidden.

M051-00K46-A004

1/99

Summary of Contents for 9500HR

Page 1: ...Lifecycle 9500HR Belt Drive Series Exercise Bikes Customer Support Services SERVICE MANUAL TM...

Page 2: ...ting 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...

Page 3: ...andlebars you ll be much more likely to stick with your exercise plan and accomplish your goals The ability to select a program to match your particular needs is what distinguishes Lifecycle bikes as...

Page 4: ...ALTERNATOR VOLTAGE TEST 18 NO HEART RATE OR DISPLAY READS NO HEART RATE 19 HANDLEBAR LIFEPULSE GRIPS LOOSE 20 SECTION II DIAGNOSTIC MODES DIAGNOSTICS STATE HOW TO ENTER 2 DIAGNOSTICS STATE OVERVIEW 3...

Page 5: ...DIAGNOSTICS STATE 15 PHOTO SHOOT 8 SOLELY USED FOR A PHOTO SHOOT SECTION III How To REMOVE AND REPLACE THE ALTERNATOR 2 ALTERNATOR BELT 3 DRIVE BELT 4 CRANK ARM AND BEARINGS 5 6 SEAT ASSEMBLY 7 MAIN W...

Page 6: ...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 7: ...1 Lifecycle 9500HR Series Exercise Bikes SECTION I TROUBLESHOOTING GUIDES...

Page 8: ...y Loose wire connections Disconnect then reconnect connections Worn or damaged wire harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute...

Page 9: ...aged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute Alternator Control...

Page 10: ...nnect connections Worn or damaged wire harnesses Inspect wire harnesses Replace worn or damaged harnesses Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Dis...

Page 11: ...nect then reconnect the connections Worn or damaged harnesses Inspect wire harnesses Replace worn or damaged harnesses Malfunctioning Alternator Control Board Test with substitute Alternator Control B...

Page 12: ...han 45 RPM Attempting to enter improper duration of time Refer to Operation Manual for time duration requirements Malfunctioning Display Console Test with substitute Display Console Replace malfunctio...

Page 13: ...nctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board Test with substitute ACB Replace defective Alternator Cont...

Page 14: ...m not available Refer to Operation Manual for program availability Keypad is cold Massage keypad with fingertips Display Console connection loose Test with substitute Display Console Replace malfuncti...

Page 15: ...ose wire connections Disconnect then reconnect connections Worn or damaged wire harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Dis...

Page 16: ...nspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Board...

Page 17: ...connect connections Worn or damaged harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display...

Page 18: ...Disconnect then reconnect connections Worn or damaged harnesses Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfu...

Page 19: ...alfunctioning Pulley Clutch or Freewheel Alternator Belt excessively tight Inspect belt deflection Adjust as necessary Alternator Belt Deflection 1 4 inch 6mm Alternator Belt Alignment is not centered...

Page 20: ...Inspect wire harnesses Replace worn or damaged harness Malfunctioning Display Console Test with substitute Display Console Replace malfunctioning Display Console Malfunctioning Alternator Control Boar...

Page 21: ...e lead Worn Battery Wires Inspect Wires Replace Wires or harness Battery leads grounding upon frame Inspect leads Replace battery Malfunctioning Display Console Test with substitute Display Console Re...

Page 22: ...rectly Adjust Foot Pads Floor surface not level Position Exercise Bike upon level surface Stabilizer Bar not attached firmly to frame Tighten attaching hardware Wheel s damaged Replace damaged wheel s...

Page 23: ...roperly or worn Inspect Bearings Adjust or replace as necessary Alternator Belt excessively loose Inspect belt deflection Adjust as necessary Alternator Belt Deflection 1 4 inch 6mm Alternator Belt wo...

Page 24: ...age 1 Attach DC voltmeter to Alternator Voltmeter positive probe to Alternator red lead Voltmeter negative lead to Alternator black lead 2 Maintain pedal speed greater than 45 RPM 3 Press START key Al...

Page 25: ...se Assembly Life Pulse handlebar Verify that the handlebar is functioning See diagrams Using an ohmmeter verify continuity between Lifepulse sensor and cable connection See wiring diagram for pin loca...

Page 26: ...Handlebar grips loosening Excessive wear or damage to grip Replace the handlebar assembly Lifepulse sensor molding loose Cleaning solution that contains an acid or ammonia base Replace the Lifepulse S...

Page 27: ...21 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 28: ...22 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 29: ...1 Lifecycle 9500HR Series Exercise Bikes SECTION II DIAGNOSTIC MODES...

Page 30: ...ENTER DIAGNOSTIC MODES Diagnostics can be entered while holding the 5 key and pressing the Start key while pedaling the bike over 45 RPM s The Enter key will prompt you forward while the Clear Pause k...

Page 31: ...ATE 6 MAXIMUM PROGRAM DURATION MAXIMUM PROGRAM TIME DIAGNOSTICS STATE 7 TELEMETRY ENABLE DISABLE TELEMETRY ENABLE DISABLE DIAGNOSTICS STATE 8 ENGLISH METRIC UNITS ENGLISH UNITS METRIC UNITS CONFIGURAT...

Page 32: ...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 Pressing the CLEAR PAUSE key will abort DIAGNOSTICS and return to the PRESS ST...

Page 33: ...ENTER key will advance to DIAGNOSTICS STATE 4 DIAGNOSTICS STATE 4 LIFEPULSE and NETWORK STATUS TESTS The PROGRAM VERSION NUMBER of the HEART RATE DSP board 05 software ex P1 80 will be displayed in t...

Page 34: ...be turned ON or OFF By default the LC9500RHR 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...

Page 35: ...AR PAUSE key will return to DIAGNOSTICS STATE 8 Pressing the START ENTER key will advance to DIAGNOSTICS STATE 10 DIAGNOSTICS STATE 10 WATTS Within this state WATTS can be enabled or disabled The UP A...

Page 36: ...ected The DOWN ARROW backs up through the list of available programs and back to the total hours displayed Pressing the CLEAR PAUSE key will return to DIAGNOSTICS STATE 12 Pressing the START ENTER key...

Page 37: ...9 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 38: ...10 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 39: ...1 Lifecycle 9500HR Series Exercise Bikes SECTION III How To SERVICE AND REPAIR GUIDES SECTION III...

Page 40: ...ATOR forward to relieve the belt tension then loop the BELT around the small FLYWHEEL SHAFT Once the BELT is free temporarily set it on top of the PULLEY to keep it out of the way STEP 6 Remove the PI...

Page 41: ...on top of the PULLEY to keep it out of the way STEP 6 Remove the three FLAT INNER E RINGS and the BENT OUTER E RING Use either two screwdrivers long nose pliers or an E Ring tool CAUTION THE E RINGS A...

Page 42: ...and slacken the belt STEP 4 Remove the three FLAT INNER E RINGS and the BENT OUTER E RING Use either two screwdrivers long nose pliers or an E Ring tool CAUTION THE E RINGS ARE UNDER LOAD PLEASE REMO...

Page 43: ...mp bolts two split washers and four bearing clamps DO NOT reuse STEP 5 Bend the outward tab of the TAB LOCK WASHER to allow rotation of the REVERSE THREADED LOCK NUT Using the 32mm crank arm wrench lo...

Page 44: ...with the bent tab facing toward the bike FRAME Slide the key of the TAB LOCK WASHER through the notch and into position against the CRANK BEARING NUT ASSEMBLY Align the flat of the bent TAB against t...

Page 45: ...ired 1 2 inch wrench Standard screwdriver 5 32 inch Hex key wrench STEP 1 Using a inch wrench remove the four mounting bolts that secure the seat to the frame STEP 2 Reassemble in the reverse order al...

Page 46: ...f 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...

Page 47: ...en 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 fing...

Page 48: ...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...

Page 49: ...t side place a 5 8 inch open end wrench on the PEDAL BOLT and turn the wrench counterclockwise STEP 3 With a phillips screwdriver remove the screw on the user right side seat post shroud Once removed...

Page 50: ...e wrench clockwise STEP 2 To remove the RIGHT PEDAL place a 5 8 inch open end wrench on the PEDAL BOLT and turn the wrench counterclockwise STEP 3 Install the new PEDALS onto the CRANK ARMS To tighten...

Page 51: ...rnal retaining pliers into the SEAT PIN RETAINING RING Guide the SEAT PIN RETAINING RING out from the SEAT PIN ASSEMBLY STEP 3 Pull the SEAT PIN PIN ASSEMBLY away from the bike frame STEP 4 Insert the...

Page 52: ...ve the two STABILIZER BOLTS from the bottom of the STABILIZER BAR Remove the STABILIZER BAR from the bike frame STEP 3 Install the new STABILIZER BAR and tighten the bolts to a torque of 25 to 30 in l...

Page 53: ...d under HOUSING Refer to SEE HOW TO in this section STEP 3 Remove the decal located on the front of the telemetry housing with a flat head screwdriver STEP 4 Using your Phillips head screwdriver loose...

Page 54: ...25 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 55: ...26 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 56: ...1 Lifecycle 9500HR Series Exercise Bikes SECTION IV WIRING BLOCK DIAGRAMS AND PARTS IDENTIFICATION SECTION IV...

Page 57: ...2 Lifecycle 9500HR Series Exercise Bikes WIRING BLOCK DIAGRAM...

Page 58: ...t Met Console Case OK36 01034 0005 Stabilizer Bar SK18 00070 0000 Leg Covers 2 OK18 01006 0000 Plunger Assembly SK18 00136 0000 Seat w Seatpost AK18 00127 0002 Seatpost AK18 00157 0000 Seat OK18 01265...

Page 59: ...r Arm Assembly AK46 00024 0002 Pulley w Plate OK46 01007 0000 Power Grip Belt Ok46 01009 0000 Crankarm Pulley Assembly AK46 00015 0000 Crankarm only OK18 01281 0000 Freewheel Pulley Assembly AK46 0001...

Page 60: ...t Met AK46 00047 0006 Jap CCD Console Case OK36 01034 0005 Stabilizer Bar SK18 00070 0000 Leg Covers 2 OK18 01006 0000 Plunger Assembly SK18 00136 0000 Seat w Seatpost AK18 00127 0002 Seatpost AK18 00...

Page 61: ...01008 0003 Idler Arm Assembly AK46 00024 0002 Pulley w Plate OK46 01007 0000 Power Grip Belt Ok46 01009 0000 Crankarm Pulley Assembly AK46 00015 0000 Crankarm only OK18 01281 0000 Freewheel Pulley As...

Page 62: ...pn Met AK46 00047 0008 Itl Eur AK46 00047 0009 Dut Eur AK46 00047 0007 Frn Met t Console Case OK36 01034 0005 Stabilizer Bar SK18 00070 0000 Leg Covers 2 OK18 01006 0000 Plunger Assembly SK18 00136 00...

Page 63: ...6 01008 0003 Idler Arm Assembly AK46 00024 0002 Pulley w Plate OK46 01007 0000 Power Grip Belt Ok46 01009 0000 Crankarm Pulley Assembly AK46 00015 0000 Crankarm only OK18 01281 0000 Freewheel Pulley A...

Page 64: ...tl Eur AK46 00048 0009 Dut Eur AK46 00048 0007 Frn Met t Console Case OK36 01034 0005 Stabilizer Bar SK18 00070 0000 Leg Covers 2 OK18 01006 0000 Plunger Assembly SK18 00136 0000 Seat w Seatpost AK18...

Page 65: ...008 0003 Idler Arm Assembly AK46 00024 0002 Pulley w Plate OK46 01007 0000 Power Grip Belt Ok46 01009 0000 Crankarm Pulley Assembly AK46 00015 0000 Crankarm only OK18 01281 0000 Freewheel Pulley Assem...

Page 66: ...11 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 67: ...12 Lifecycle 9500HR Series Exercise Bikes NOTES...

Page 68: ...1 Lifecycle 9500HR Series Exercise Bikes SECTION IV WIRING BLOCK DIAGRAMS AND PARTS IDENTIFICATION SECTION IV...

Page 69: ...2 Lifecycle 9500HR Series Exercise Bikes WIRING BLOCK DIAGRAM...

Page 70: ...1 Lifecycle 9500HR Series Exercise Bikes SECTION V MISCELLANEOUS INFORMATION SECTION V...

Page 71: ...2 Lifecycle 9500HR Series Exercise Bikes MODEL IDENTIFICATION and SERIAL NUMBER LOCATION Serial Number...

Page 72: ...side C Outside C Alternator Control C Heatsink C Connectors I I Board I Drive Belt I Crank Bearings I Pedals C I Pully Clutch C L Alternator Flywheel C Seat Post Shaft C Plunger Assembly I Seat Top Su...

Page 73: ...oblem 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 d...

Page 74: ...M 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 RECEIV...

Page 75: ...6 Lifecycle 9500HR Series Exercise Bikes NOTES...

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