Life Fitness 95L Service Manual Download

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Models 95L, 95LWEZ, and 95LE

Summit Trainers

Customer Support Services

SERVICE MANUAL

Summary of Contents for 95L

Page 1: ...Models 95L 95LWEZ and 95LE Summit Trainers Customer Support Services SERVICE MANUAL...

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Page 3: ...2 Load resistance varies during operation continued 23 Unable to change audio level 23 No audio to headphones 23 Unable to receive stations when using cable 23 TV picture has snow like appearance 23 L...

Page 4: ...MENU 65 INFORMATION STATISTICS 66 SOFTWARE VERSIONS 67 SYSTEM ERRORS 68 USAGE LOG REPORT 69 CONFIGURATION MENU 70 MANAGER S CONFIGURATION 71 CUSTOM MESSAGE SETUP 72 MANUFACTURER S CONFIGURATION MENU...

Page 5: ...104 HOW TO REPLACE THE LOWER BELT 106 HOW TO REPLACE THE 6V BATTERY 107 HOW TO REPLACE THE POWER CONTROL BOARD 108 HOW TO REPLACE THE FLEXONIC BELTS 109 HOW TO REPLACE THE POLY V PULLEYS 110 HOW TO RE...

Page 6: ...Models 95L 95LWEZ and 95LE Summit Trainers Table of Contents 4...

Page 7: ...Models 95L 95LWEZ and 95LE Summit Trainers INTRODUCTION...

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Page 9: ...UIDES ELECTRONICS INDEX Refer to the table of contents for section subtopics When an operating problem occurs attempt to isolate the cause by referring to the troubleshooting guides and diagnostic tes...

Page 10: ...Models 95L 95LWEZ and 95LE Summit Trainers Using This Manual 8...

Page 11: ...ian Model number Serial number a 3 letter 6 number sequence Symptom of problem Phone technicians are available Monday through Friday from 8 00 AM to 5 00 PM Central time Fax numbers are active 24 hour...

Page 12: ...Models 95L 95LWEZ and 95LE Summit Trainers Contacting Customer Support 10...

Page 13: ...Lifepulse and telemetry are all managed by the microprocessor The console sends a PWM signal to the power control board to control the duty cycle of the load HR TELEMETRY HR Telemetry is implemented v...

Page 14: ...Models 95L 95LWEZ and 95LE Summit Trainers Theory of Operation 12...

Page 15: ...ation Lifepulse System used to simulate a user s heart rate detects electrical impulses in the hands digitizes them and processes the signal using a digital signal processor MET Metabolic Equivalent t...

Page 16: ...Models 95L 95LWEZ and 95LE Summit Trainers Terminology 14...

Page 17: ...Models 95L 95LWEZ and 95LE Summit Trainers TROUBLESHOOTING...

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Page 19: ...d Collar exceeds 005 Adjust and tighten collar so that gap between collar and rocker arm is 005 Noisy operation Timing belt assembly worn excessively Replace belt Burning odor New machine A new Summit...

Page 20: ...Reposition magnet close to reed switch Verify an open circuit between pins 2 and 3 and continuity between pins 1 and 3 Replace reed switch No power Reed switch improperly positioned Verify that reed...

Page 21: ...itch is properly positioned in relation to magnet Faulty display console Verify voltages at display console connections Substitute a working display console Replace display console Faulty alternator c...

Page 22: ...d Display console dim Worn overlay bezel assembly Perform keypad test Replace display console Insufficient battery voltage Verify battery voltage is at least 6 3 VDC Faulty connection Verify connectio...

Page 23: ...ical was used Enter Diagnostics and perform the Lifepulse test Replace Lifepulse sensors Lifepulse sensors loose Sensor mounting hardware loose Check for Loose Lifepulse sensors Replace Lifepulse sens...

Page 24: ...alternator Repair connections Faulty alternator brushes Inspect alternator brushes Brushes should be of approximate equal length not cracked or less than long Replace faulty alternator brushes Faulty...

Page 25: ...e Faulty keypad Perform keypad diagnostic Unable to change audio level Faulty interface board Replace Interface board Faulty headphone User s headphone assembly may be defective Faulty headphone jack...

Page 26: ...D screen Replace touchscreen LCD screen illuminated but blank Faulty computer board Replace computer board Faulty LCD backlight Replace touchscreen LCD screen is dark Faulty backlight power inverter R...

Page 27: ...Models 95L 95LWEZ and 95LE Summit Trainers LED DIAGNOSTICS...

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Page 29: ...Models 95L 95LWEZ and 95LE Summit Trainers LED Diagnostics 27 95L DISPLAY CONSOLE...

Page 30: ...NSOLE T ext to print PMS 346C All LED s and Display Windows are tinted 10027 Black or approved equivalent sample All LED s and Display Windows are tinted 10027 Black or approved equivalent sample All...

Page 31: ...Models 95L 95LWEZ and 95LE Summit Trainers LED Diagnostics 29 95LE DISPLAY CONSOLE...

Page 32: ...est Telemetry Language All LEDs On Keypad Test Relay Fld Kick Fld Control System Voltage Reed Switch RPM All RPM Field Duty Cycle Alt Voltage Alt Reed RPM Load Duty Cycle Max Duration Units Watts Disp...

Page 33: ...e 0000 BOOT LOADER VERSION example BOOT VER Press ENTER for access to the optional settings see map on page 30 While pressing and holding COOL DOWN press ENTER for the test service menu T ext to print...

Page 34: ...Text to print PMS 346C All LED s and Display Windows are tinted 10027 Black or approved equivalent sample All LED s and Display Windows are tinted 10027 Black or approved equivalent sample All LED s a...

Page 35: ...LED Press ENTER to advance to the next diagnostic state Press CLEAR to return to the previous state Press CLEAR repeatedly to exit diagnostics T ext to print PMS 346C All LED s and Display Windows are...

Page 36: ...will toggle the speaker on and off Pressing the 0 key will toggle the RPM display between the alternator RPM and the reed switch RPM The ENTER key LED will be on when the alternator RPM is displayed R...

Page 37: ...on This is useful because it will indicate the voltage of the 6 volt battery Note since the current has gone through several voltage drops this voltage will be lower than when readings are taken at th...

Page 38: ...turn to the previous state Press CLEAR repeatedly to exit diagnostics T ext to print PMS 346C All LED s and Display Windows are tinted 10027 Black or approved equivalent sample All LED s and Display W...

Page 39: ...hands on conditions occur The first timer located on the upper console message center display stops when Lifepulse computes and displays an initial peak detected heart rate The second timer is located...

Page 40: ...rk receives the CSAFE communication packet from the console and responds with a configuration communication packet the console will display RECEIVING 4 If the network does not respond to the console a...

Page 41: ...eted successfully the message EEPROM GOOD will appear If the test fails EEPROM BAD AT will display with the faulty location Press ENTER to advance to the next diagnostic state Press CLEAR to return to...

Page 42: ...window The ENTER key LED indicates when the value is at the default on setting This value is stored in EEPROM and is kept when the unit is turned off Press ENTER to advance to the next diagnostic stat...

Page 43: ...lluminates when defaulted to SYSTEM BEEPS ON This value is stored in EEPROM and is kept when the cross trainer is not in use Press the ENTER key to advance to the next Diagnostic State Press the CLEAR...

Page 44: ...the ENTER key to advance to the next Diagnostic state Press the CLEAR key to got to the previous diagnostic state Press the CLEAR key repeatedly to exit Diagnostics T ext to print PMS 346C All LED s a...

Page 45: ...s set to the default English This value is stored in EEPROM and is kept when the unit is turned off This is the final diagnostic state in TEST SERVICE Press CLEAR to return to the previous state Press...

Page 46: ...LED indicates when the value is at the default 60 minutes This value is stored in EEPROM and is kept when the unit is not in use Press ENTER to advance to the next diagnostic state Press CLEAR to ret...

Page 47: ...n This value is stored in EEPROM and is kept when the unit is turned off Press ENTER to advance to the next diagnostic state Press CLEAR to return to the previous state Press CLEAR repeatedly to exit...

Page 48: ...when the default watts on setting has been chosen This value is stored in EEPROM and is kept when the unit is turned off Press ENTER to advance to the next diagnostic state Press CLEAR to return to th...

Page 49: ...hen the default METS on setting has been chosen This value is stored in EEPROM and is kept when the unit is turned off Press ENTER to advance to the next diagnostic state Press CLEAR to return to the...

Page 50: ...dicates when the default on setting has been chosen This value is stored in EEPROM and is kept when the unit is turned off Press ENTER to advance to the next diagnostic state Press CLEAR to return to...

Page 51: ...he UP ARROW key allows scrolling through the available programs and indicates the number of times each has been chosen The DOWN ARROW key backs through the same list shown in the table Press ENTER to...

Page 52: ...this does not turn on or off the power to the CSAFE port Press ENTER to advance to the next diagnostic state Press CLEAR to return to the previous state Press CLEAR repeatedly to exit diagnostics T e...

Page 53: ...er the workout has been completed the unit will return to the default language of the unit e g an English unit used in French will return to English after the workout Press the ENTER key to advance to...

Page 54: ...c sessions This is the final diagnostic state Press CLEAR to return to the previous state Press CLEAR repeatedly to exit diagnostics T ext to print PMS 346C All LED s and Display Windows are tinted 10...

Page 55: ...Models 95L 95LWEZ and 95LE Summit Trainers LCD DIAGNOSTICS...

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Page 57: ...LWEZ and 95LE Summit Trainers LCD Diagnostics 55 WELCOME SCREEN The Welcome Screen appears immediately after power up and when then unit is not in use Touching the screen will bring up the Workout Sel...

Page 58: ...nter the Systems Option Menu from the Workout Selection Screen hold down the COOLDOWN key and double tap the Life Fitness icon After entering the System Options the Main Menu will appear Refer to the...

Page 59: ...Trainers LCD Diagnostics 57 SYSTEMS OPTIONS MAIN MENU The System Options Main Menu selections allow access to the System Test Menu Information Menu and Configuration Menu Press the Exit key to return...

Page 60: ...s LCD Diagnostics 58 SYSTEM TEST MENU The System Test Menu allows access to the Systems Diagnostics Telemetry Test Lifepulse Test CSAFE Network Test and EEPROM Test screens Press the Exit key to retur...

Page 61: ...tivated to produce a load the higher the number the harder it is to pedal KEYPAD VALUE displays an acknowledgement when a key is pressed on the console LOAD DUTY CYCLE controls the current Load Duty C...

Page 62: ...rainers LCD Diagnostics 60 TEST ENGINEERING All status windows on this screen should display OFF and should be changed only at the direction of Life Fitness Customer Support Press the BACK key to retu...

Page 63: ...te whether Telemetry is enabled or disabled Telemetry can be toggled on and off by pressing the corresponding circle When Telemetry is enabled the user s heart rate is displayed in the Heart Rate Valu...

Page 64: ...on Time window The timer stops when a reading appears in the Heart Rate Value window The Gain and Confidence Level values are displayed in the appropriate windows Gain indicates the strength of the he...

Page 65: ...e Summit Trainer s connectivity features are functioning properly Follow the on screen instructions to perform the CSAFE loopback test The responses Ready Running and either Pass or Fail will appear i...

Page 66: ...ERNAL TEST key to test the EEPROM on the single board computer Press the EEPROM EXTERNAL TEST key to test the interface board s EEPROM In either test a PASS message indicates a good EEPROM Press the B...

Page 67: ...ut program usage and critical system power levels SOFTWARE VERSIONS information about current software versions SYSTEM ERRORS historical information on system errors encountered during operation USAGE...

Page 68: ...stics 66 INFORMATION STATISTICS Statistics such as total hours of use and hours of use per program can be seen on this screen Press the BACK key to return to the Systems Options Main Menu screen Press...

Page 69: ...WARE VERSIONS This screen displays the unit s current software versions and where applicable their corresponding Life Fitness part numbers Press the BACK key to return to the Systems Options Main Menu...

Page 70: ...CD Diagnostics 68 SYSTEM ERRORS System errors that have been logged into the unit s memory can be seen on this screen Press the BACK key to return to the Systems Options Main Menu screen Press the MAI...

Page 71: ...cs 69 USAGE LOG REPORT The Usage Log Report allows the user to see detailed information regarding the RPMs used at various levels Press the BACK key to return to the Systems Options Main Menu screen P...

Page 72: ...to this information MANAGER supervisory workout parameter setup MANUFACTURER critical system parameter setup TV Television configuration TOUCHSCREEN CONFIGURATION touchscreen proximity calibration Pr...

Page 73: ...IMEOUT Sets the amount of time from 20 to 255 seconds the user can go without touching the screen before the console resets to the Welcome screen The default is 60 seconds PAUSE TIME Sets the amount o...

Page 74: ...Message Setup Enter the message using the on screen keyboard shown in the illustration The shift key is used to input capital letters and special characters The message will scroll across the top of t...

Page 75: ...gnostics 73 MANUFACTURER S CONFIGURATION MENU Access to this screen is available only to certified Life Fitness technicians Press the BACK key to return to the Systems Options Main Menu screen Press t...

Page 76: ...press AUTO to return CHANNEL SETUP to AUTO To restore a channel In CHANNEL SETUP press MANUAL then use the CH DOWN and CH UP controls to change channels Press ADD to add a channel then press AUTO to...

Page 77: ...llows managers to compensate for the average ambient noise levels in their clubs The maximum volume returns to this default after each workout The lower pair of arrow keys control the unit s current v...

Page 78: ...configure the touchscreen The display will show a blank screen with a plus sign in the middle Follow the directions at the top of the screen to properly reconfigure the touchscreen This procedure may...

Page 79: ...Models 95L 95LWEZ and 95LE Summit Trainers HOW TO SERVICE REPAIR GUIDES...

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Page 81: ...UPPORT COVER Tool required Phillips screwdriver Estimated repair time 10 minutes 1 Remove the console support cap by squeezing the sides and pulling it away from the console support 2 Remove the two P...

Page 82: ...quired Phillips screwdriver Estimated repair time 15 minutes 1 Remove the console support cover see How To on page 79 2 Remove the four Phillips screws that secure the console to the console support 3...

Page 83: ...e the four bolts that secure the handlebar assembly to the monocolumn The bolts will be visible after the bullhorn covers have been removed 6 Remove the two Phillips screws that secure the accessory t...

Page 84: ...on page 79 2 Remove the console see How To on page 80 3 Remove the accessory tray see How To on page 81 4 Remove the Torx bolts that secure the console support to the main upright There are six bolts...

Page 85: ...t Deadshaft Cover Rear Deadshaft Cover HOW TO REPLACE THE OUTER DEADSHAFT COVERS Tool required Phillips screwdriver Estimated repair time 10 minutes 1 Remove the two screws that secure the outer deads...

Page 86: ...O REPLACE THE HANDLEBAR WITH GRIP Tools required Phillips screwdriver T 45 Torx bit ratchet with extension Estimated repair time 30 minutes 1 Remove the Outer deadshaft covers see How To on page 83 2...

Page 87: ...screwdriver Estimated repair time 30 minutes 1 Remove the two screws that secure the Lifepulse sensors to the bullhorn 2 Disconnect the heart rate cable from the Lifepulse sensors 3 Reverse steps 1 a...

Page 88: ...river Estimated repair time 15 minutes 1 Remove the six screws that secure either of the main shrouds to the frame 2 Remove that shroud 3 Repeat the procedure for the opposite side 4 Reverse steps 1 t...

Page 89: ...lly tip the unit to one side and place a 4 X 4 block or equivalent under the rear stabilizer The lower track cover cannot be removed without tipping the unit slightly 3 Remove the three bolts and wash...

Page 90: ...r that secure the bullhorn covers to the bullhorns 4 Remove the bullhorn covers 5 Disconnect the heart rate cables from the bullhorns 6 Remove the four Torx bolts that secure the handrail assembly to...

Page 91: ...e the main shroud assembly see How To on page 86 2 Remove the accessory tray see How To on page 81 3 Disconnect one end of the console cable assembly from the console 4 Disconnect the other end from t...

Page 92: ...SSEMBLY CONTINUED 8 Fasten the 16 pin console connector end of the new cable to the fish tape with electrical tape as shown 9 Use the fish tape to feed the console cable up through the frame and monoc...

Page 93: ...e four Torx bolts that secure the handrail assembly to the monocolumn 3 Remove the four Torx bolts that secure the handrail assembly to vertical uprights 4 Remove the handrail assembly 5 Remove the th...

Page 94: ...ated repair time 10 minutes 1 Remove the two Phillips screws that secure the outer rocker cover to the inner rocker cover assembly and rocker arm 2 Remove the rocker arm cover 3 Reverse steps 1 throug...

Page 95: ...r rocker arm cover See How To on page 92 2 Remove the two Phillips screws that secure the lever joint cover bracket to the rocker arm 3 Remove the lever joint cover assembly 4 Reverse steps 1 through...

Page 96: ...ly see How to on page 93 3 Remove the snap ring that holds the rocker arm on the control link shaft 4 Carefully separate the control link from the rocker arm Note the orientation of the thrust washer...

Page 97: ...Remove the four Torx bolts that secure the handrail assembly to the deadshaft 7 Remove the three hex bolts that secure the monocolumn to the frame 8 Carefully lift the monocolumn out of the frame and...

Page 98: ...that secure the rocker arm to the deadshaft 5 Remove the screws that secure the lever joint cover bracket to the rocker arm 6 Remove the snap ring that holds the rocker arm onto the control link shaft...

Page 99: ...ix Torx bolts that secure the pedal adaptor to the truck assembly 2 Remove the pedal adaptor assembly from the unit 3 Remove four Allen head bolts that secure the pedal to the pedal adaptor 4 Reverse...

Page 100: ...late 4 Carefully slide the upper track cover mounting bracket and remaining cover up until the assembly is free of the lower track cover bracket 5 To ease removal of the track cover position the corre...

Page 101: ...ated repair time 1 hours 1 Remove the main shrouds see How To on page 86 2 Remove the lower track cover see How To on page 87 3 Remove the control link from the pedal adaptor see How To l on page 102...

Page 102: ...e pedal adaptor from the pedal extrusion 7 Remove tension on the timing belt 8 Remove the front screw that holds the upper belt mounting bracket 9 Rotate the belt terminator bracket 10 Separate the pe...

Page 103: ...nstall the new truck roller assembly 15 Reposition the pedal tube 16 Reassemble the unit in reverse order 17 Slide the assembly up and down the pedal tube to ensure that all rollers are engaged and tu...

Page 104: ...e pedal adaptor 5 Remove the Allen bolt and washer that secure the control link assembly to the pedal adaptor 6 Remove the snap ring that holds the rocker arm to the control link shaft 7 Carefully rem...

Page 105: ...pliers Estimated repair time 10 minutes 1 Remove one of the pushnuts from one end of the wheel shaft assembly 2 Slide the wheel off the shaft 3 Slide the wheel shaft and remaining wheel out of the fr...

Page 106: ...ee How To on page 87 3 Scribe the position of the tension bracket before loosening the mounting bolts and tensioning bolt 4 Loosen the three tension bracket mounting bolts 5 Loosen the tensioning bolt...

Page 107: ...it Trainer 10 Install one end of the new upper belt to one of the pedal truck assemblies 11 Route the belt through the clutch sprockets and pulley 12 Install the other end of the upper belt to the oth...

Page 108: ...dal truck assembly 5 Scribe the position of the tension bracket before loosening three tension bracket mounting bolts 6 Loosen the tensioning bolt until the tension bracket is as loose as possible 7 I...

Page 109: ...tchet Estimated repair time 20 minutes 1 Remove the user s right side main shroud assembly see How To on page 86 2 Disconnect the red and black wires from the 6V battery 3 Remove the two Torx screws t...

Page 110: ...entify and tag wiring at the power control board 3 Disconnect the wiring from the power control board 4 Remove the four screws that secure the power control board to the mounting plate 5 Use the same...

Page 111: ...nd slowly walk the belt onto the clutch pulley until it is centered b For an alternator belt place the new belt around the alternator pulley and slowly walk it onto the intermediate pulley until it is...

Page 112: ...aft 4 Remove the Torx screw and washer that secure the lower Poly V pulley to the clutch pulley shaft 5 Remove the two set screws on the lower Poly V pulley and slide it off the clutch pulley shaft 6...

Page 113: ...of the clutch pulley shaft assembly 5 Remove the two Allen screws that secure the bearing retainer to the bearing housing 6 Remove the bearing retainer 7 Slide the clutch pulley shaft assembly out of...

Page 114: ...he alternator see illustration 5 Disconnect all wires attached to the alternator 6 Remove the hex nut and mounting bolts that secure the alternator to the frame 7 Install the new alternator in reverse...

Page 115: ...the main shrouds see How To on page 86 2 Remove the lower track cover see How To on page 89 3 Remove the Allen screw that secures the spring to the pedal truck assembly or frame 4 Remove the spring 5...

Page 116: ...es on the alternator 3 Disconnect all wires attached to the alternator 4 Disconnect the connector end of the cable from the power control board at P2 A new cable is included with the new resistor brac...

Page 117: ...timated repair time 20 minutes 1 Remove the main shrouds see How To on page 86 2 Disconnect the reed switch cable from the power control board 3 Remove the two Torx screws that secure the reed switch...

Page 118: ...ft 5 Scribe the position of the tension bracket 6 Loosen the tension bracket mounting bolts 7 Loosen the tensioning bolt until the tension bracket is as loose as possible 8 Slide the upper belt off th...

Page 119: ...TS CONTINUED 13 Reinstall the Poly V pulley 14 Tighten the tensioning bolt until the tension bracket returns to original position 15 Tighten the tension bracket mounting bolts 16 If it was removed in...

Page 120: ...acket 6 Loosen the tension bracket mounting bolts 7 Loosen the tensioning bolt until the tension bracket is as loose as possible 8 Slide the upper belt off the clutch sprockets 9 Remove the snap ring...

Page 121: ...Note the orientation of Thrust and hardened washers so they may be reassembled in the proper order 12 Remove a second snap ring 13 Slide the clutch shaft out of the user s right side of the frame 14 R...

Page 122: ...Models 95L 95LWEZ and 95LE Summit Trainers How To 120...

Page 123: ...Models 95L 95LWEZ and 95LE Summit Trainers ELECTRONICS...

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Page 125: ...Models 95L 95LWEZ and 95LE Summit Trainers Electronics 123 WIRING BLOCK DIAGRAM MODEL 95L AND 95LWEZ...

Page 126: ...K DIAGRAM MODEL 95LE Coax Cable Access Panel DC Power Cable Flat flex Cable Polar Receiver Cable Power Cable To SBC HR Extension Cable Power Control Cable Heart Rate Cable in User Arm L or R Console C...

Page 127: ...Models 95L 95LWEZ and 95LE Summit Trainers INDEX...

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Page 129: ...cals caustic 21 chest strap 21 cleaning solution 21 clevis cover assemblies 95 clutch 17 clutch pulley assembly 111 clutch pulley bearings 17 clutch shaft bearing housing 118 clutch shaft bearings 17...

Page 130: ...noperative 21 heart rate value 61 HEART RATE VALUE window 62 HEART RATE window 34 35 heart shape 40 help Life Fitness customer support 9 HILL program 49 HOUR program 49 hours of use 66 HR heart rate 1...

Page 131: ...rt 9 photo shoot 52 pins 18 19 Polar 13 21 Poly V pulleys 110 port I 0 test 36 Portuguese 43 72 power control board 11 108 power up message 38 power no 18 PRE SET program 49 PROFILE window 37 program...

Page 132: ...n 70 76 touchscreen doesn t respond to touch 24 touchscreen proximity calibration 70 touchscreen erratic operation 24 transmitter faulty 21 troubleshooting 17 truck roller assembly 99 TV 70 TV configu...

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Page 134: ...are registered trademarks Heart Rate Zone Training and RELY ON IT are trademarks of Brunswick Corporation Polar is a registered trademark of Polar Electro Inc Any use of these trademarks without the e...

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Life Fitness 95L, Service Manual

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