LifeFitness CT 90X 93X 95Xi 95Xe Service Manual

7/21/2019 LifeFitness CT 90X 93X 95Xi 95Xe Service Manual

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Fixed Stride Cross-Trainers

90X, 93X, 95Xe and 95Xi

Customer Support Services

SERVICE MANUAL


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Life Fitness Cross-Trainers 93X, 95Xe, and 95Xi with Quiet DriveTable of Contents

TABLE OF CONTENTS

INTRODUCTION ................................................................................. 5Introduction............................................................................. 7Special Service Tool Requirements ................................................. 8Glossary.................................................................................. 9

TROUBLESHOOTING GUIDE...................................................................11No power.......................................................................13Console lights then fails ..................................................... 13No LEDs or random LEDs lit on display .................................... 13Unit auto starts but does not read RPM................................... 13Unit does not auto start ..................................................... 14No load .........................................................................14Noisy operation ...............................................................14Erratic heart rate from Lifepulse sensors.................................15

No heart rate from Lifepulse sensors......................................15No heart rate reading using Polar transmitter ........................... 16Erratic heart rate using the Polar transmitter ........................... 16Screen is blank ................................................................16Channels do not change ..................................................... 16Sound does not change ......................................................16No sound .......................................................................17Unable to receive any channels when using cable ......................17Snow on the screen...........................................................17Screen is dark .................................................................17Screen does not respond to touch .........................................17Wrong buttons activate when the screen is touched ................... 17

Troubleshooting Guide Testing the Inverter Board ............................ 18Troubleshooting Guide Testing the Power Supply Cable......................19

LCD DIAGNOSTICS .............................................................................21Welcome Screen ......................................................................23Workout Selection Screen ........................................................... 24System Options Main Menu ........................................................25System Test Menu.....................................................................26System Diagnostics....................................................................27Test Engineering ......................................................................28Telemetry Test ........................................................................29CSAFE Network Test ................................................................. 31

EEPROM Test........................................................................... 32Information Menu .....................................................................33Information Statistics ................................................................34Software Versions.....................................................................35System Errors ..........................................................................36Usage Log Report ..................................................................... 37Configuration Menu................................................................... 38Managers Configuration.............................................................39


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2

Custom Message Setup ...............................................................40

Manufacturers Configuration Menu................................................41TV Setup................................................................................42Max Volume Setup ....................................................................44Touchscreen Configuration..........................................................45

LED DIAGNOSTICS..............................................................................4793X Display Console...................................................................4995Xi Display Console..................................................................50Map ......................................................................................51Entry Level .............................................................................52Test/Service All LEDs and Keypad Test............................................53Test/Service Walking LED Test....................................................54Test/Service Miscellaneous Tests 1 ..............................................55

Test/Service Miscellaneous Tests 2 ..............................................57Test/Service Port I/O Test.........................................................58Test/Service Lifepulse Test .......................................................59Test/Service CSAFE Network Test ................................................61Test/Service EEPROM Test.........................................................62Test/Service Telemetry Enable/Disable.........................................63Test/Service Language .............................................................64Optional Settings Max Program Duration ........................................65Optional Settings English/Metric Units ..........................................66Optional Settings Watts Display Enable/Disable ...............................67Optional Settings METS Display Enable/Disable................................68Optional Settings Cal/Hr Display Enable/Disable ..............................69Optional Settings Total Hours and Statistics....................................70Optional Settings Entertainment Controls On/Off .............................71Optional Settings Photo Shoot ....................................................72

How To........................................................................................73How To Replace the Console Support Cover....................................75How To Replace the Console Assembly..........................................76How To Replace the Accessory Tray .............................................77How To Replace the Console Support Bracket .................................78How To Replace the Bullhorns ....................................................79How To Replace the Deadshaft Covers ..........................................80How To Replace the Handlebars..................................................81

How To Replace the Lifepulse Sensors ..........................................82How To Replace the Front Frame Cover ........................................83How To Replace the Main Shroud Assembly ....................................84How To Replace the Ladder Frame Cover.......................................85How To Replace the Console Cable Assembly ..................................86How To Replace the Lower Shroud Panels ......................................87How To Replace the Outer Lever Joint Cover and Rocker Arm Cover......88How To Replace the Inner Lever Joint Cover and Inner Rocker Arm Cover89

TABLE OF CONTENTS


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LCD Diagnostic

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How To Replace the Rocker Arm .................................................90How To Replace the Outer Link Cover........................................... 91How To Replace the Pedal Lever Assembly.....................................92How To Replace the Control Link Assembly .................................... 93How To Replace the Crank Arm Cover...........................................94How To Replace the Main Drive Belt.............................................95How To Replace the Battery ......................................................96How To Replace the Reed Switch Cable Assembly ............................ 97How To Replace the Power Control Board ......................................98How To Replace the Alternator Belt .............................................99How To Replace the Poly-V Pulley ............................................. 100How To Replace the Alternator................................................. 101How To Replace the Pedal ...................................................... 102

How To Replace the Resistor Bracket Assembly ............................. 103How To Replace the Magnet and Standoff Assembly........................ 104How To Replace the Right Crank Arm ......................................... 105How To Replace the Left Crank Arm/Pulley Assembly...................... 106How To Replace the Pedal/Rocker Shaft Bearings .......................... 107How To Replace the Crossover Shaft and/or Crossover Bearings ......... 110How To Replace the Crankshaft and/or Crankshaft Bearings.............. 114LCD Integrated Console Overview................................................ 119How To Replace the Headphone Jack ......................................... 120How To Replace the Inverter Board............................................ 121How To Replace the Single Board Computer ................................. 122How To Replace the Interface Board .......................................... 123

How To Replace the Touchscreen Assembly.................................. 124ELECTRONICS ................................................................................ 125

Wiring Block Diagram Model 93X................................................ 127Wiring Block Diagram Model 95Xi............................................... 128Wiring Block Diagram Model 95Xe .............................................. 129

MISCELLANEOUS ............................................................................. 131Model Identification and Serial Number Location ............................. 133Preventive Maintenance Schedule ............................................... 134Safety Instructions.................................................................. 135

INDEX.......................................................................................... 135Index .................................................................................. 137

TABLE OF CONTENTS


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Quiet Drive Cross-Trainer

INTRODUCTION


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Life Fitness Cross-Trainers 93X, 95Xe, and 95Xi with Quiet Drive

Introduction

7

INTRODUCTION

This service manual covers Life Fitness Cross-Trainers 93X, 95Xe, and 95Xi with theQuiet Drive module. If an operating problem should arise, turn to thetroubleshooting guides and attempt to isolate what is causing the malfunction. Theguides are listed by symptoms and contain suggestions regarding the most probablecause of the problem. Once you have pinpointed the source of the problem, turnto the appropriate "How To..." section and review the proper procedures forremoving, replacing or adjusting a part. The "How To..." sections are organized byreplaceable part (or assembly). Each page lists any special tools required tocomplete the task. If you do not have a part in stock, call Life Fitness CustomerSupport Services any Monday through Friday from 8:00 AM to 6:00 PM (Centraltime). When you place a call, in order to speed our response, please have thefollowing information available for the customer service phone technician:

1. The cross-trainer model number

2.

The serial number

3.

The symptom of the problem

4. The part name and number to order

When you receive your order, review the appropriate "How To..." section andfollow the step-by-step procedures designed to help you install the part quicklyand correctly. If you have any questions or comments please phone, mail, or fax usat:

LIFE FITNESS - CUSTOMER SUPPORT SERVICES

5100 River Road, Schiller Park, IL 60176, U.S.A.

Telephone: 847-451-0036, Toll Free: 800-351-3737, FAX: 847-288-370


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Introduction

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SPECIAL SERVICE TOOL REQUIREMENTS

Unless otherwise specified, only basic hand tools are required to perform serviceprocedures outlined in the How To section. Some of these standard tools are

Phillips and slotted screwdrivers, Torx bits, pliers, a rubber mallet, a pry bar, snapring pliers (internal and external), English and metric socket wrenches (3/8 or1/2 drive), and combination, open-end, or box wrenches in both English andmetric sizes.

Specialized tools required for some service procedures are listed immediatelybelow their subheadings. Specialized tools must be used to safely and effectivelycomplete the service procedures. Improvisation or attempts to use any other toolcould result in personal injury or unnecessary damage to the equipment.


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Introduction

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GLOSSARY

The following words and acronyms are commonly referenced in this manual.

Expression Meaning

Connectors Electrical plugs used to connect wiring into electrical component.

Display console board Electronic board for making settings and monitoring physical output.

EEPROM Electrically Erasable Programmable Read Only Memory.

EEROM Electrically Erasable Read Only Memory.

LDC Load Duty Cycle.

LED Light Emitting Diode --used to show a state of operation

Lifepulse Heart rate sensors on hand grips

PCBPower Control Board --regulates voltage to the alternator, console,and battery.

Polar Receiver A device directly in front of the operator that monitors heart rate.

Rear Drive The area where all the drive components reside.

RPMRevolution Per Minute --describes the number of times somethingturns in a minute.


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Introduction

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Life Fitness Cross-Trainers 93X, 95Xe, and 95Xi with Quiet DriveTroubleshooting

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TROUBLESHOOTING GUIDE

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Faulty battery Using multi-meter, verify that the battery

voltage is greater than 6 volts DC. Replacebattery if voltage is below 6 volts.

Main cable connection Verify that the main cable is plugged into boththe console and the power control board.Check for loose wires at connectors. Replaceas necessary.

Faulty reed switch Using a multi-meter, verify the continuity ofthe reed switch cable assembly (see wiringdiagram). Replace the reed switch, ifnecessary.

No power

Magnet Verify the presence of the magnet on the drivepulley. Install a new one if it is missing.

Faulty battery Using a multi-meter, verify that the battery

voltage is greater than 6 volts DC. Replace thebattery if the voltage is below 6 volts.

Console lights

then fails

Faulty reed switch Using a multi-meter, verify continuity of thereed switch cable assembly (see wiringdiagram). Replace the reed switch ifnecessary.

Faulty battery Using a multi-meter, verify that the batteryvoltage is greater than 6 volts DC. Replace thebattery if the voltage is below 6 volts.

Faulty cable connection ordamage to main cable

Verify that the main cable is properly pluggedinto the console. Inspect the main cable fordamage or crimps. Using a multi-meter, verifycontinuity of the main cable.

No LEDs orrandom LEDs liton display

Faulty console or powercontrol board

Using a multi-meter, verify 6 volts DC at theconsole connector pins 4 (+) and 11 (GND). Ifvoltage is present, replace the console. If not,replace the power control board.

Unit auto startsbut does notread RPM

Faulty cable or faulty cableconnection

Verify the cable connections at the console,power control board, and alternator. Check forloose wires and/or connectors. Using a multi-meter, verify continuity of all cablesassociated with these components. Replaceany defective cables.


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Faulty battery Using a multi-meter, verify thatthe battery voltage is greater

than 6 volts DC. Replace thebattery if it is below 6 volts.

Magnet Verify the presence of themagnet on the drive pulley. If notpresent, install a new one.

No RPM Operator must be pedaling theunit to activate the auto startfeature.

Faulty cable connection atthe console, power controlboard, or reed switch

Verify that the cable connectionsat the console, power controlboard, and reed switch areproperly plugged in. Using amulti-meter, verify continuity on

all cables. Replace defectivecables.

Unit does not auto start

Faulty power control board Using a multi-meter, verifycontinuity on the reed switchcable and the main cable. If bothare good, replace the powercontrol board.

No load Faulty cables, power controlboard, or alternator

Verify the cable connections atthe console, power control board,and alternator. Check for loosewires and/or connectors. Using amulti-meter, verify continuity ofall cables associated with these

components. Enter diagnosticstate 3, execute the field dutycycle test, and increase the dutyload. If the load does notincrease, replace the alternator.

Loose or missing hardware Verify that all hardware ispresent, has been tightened, andthat Loctite 242 is applied wherenecessary.

Pedal rollers worn or dirty Inspect pedal rollers for debris orwear and replace as necessary.

Debris in pedal roller track Clean pedal roller track.

Worn bearings Replace bearings and associated

shaft.

Noisy operation

Alternator Relieve tension on the alternatorbelt and spin the flywheel tocheck for smooth operation.Thumping indicates a faultyalternator. Replace thealternator.


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Lifepulse sensors dirtyfrom usage or from beingcleaned with incorrectsolution

Clean Lifepulse sensors with mildsoap and water. Replace the sensorsif condition warrants.

User is repositioning handswhile acquiring a heartrate reading

Instruct user on proper technique foracquiring heart rate readings.

Erratic heart rate fromLifepulse sensors

Pinched heart rate cable Remove deadshaft covers andconsole. Inspect the connectionbetween the user arm heart ratecables and the console heart ratecable. Using a multimeter, verifycontinuity from the hand sensors to

the heart rate cable connector at theback of the console. Check fromhand sensor to frame ground toverify presence of shorts. Then checkfor an electrical short between thehand sensor and the frame. Replaceany defective cables.

Pinched heart rate cable Remove deadshaft covers andconsole. Inspect the connectionbetween the user arm heart ratecables and the console heart ratecable. Using a multimeter, verifycontinuity from the hand sensors to

the heart rate cable connector at theback of the console. Check fromhand sensor to frame ground toverify presence of shorts. Then checkfor an electrical short between thehand sensor and the frame. Replaceany defective cables.

Faulty heart rate cableconnection

Remove deadshaft covers andconsole. Inspect the connectionbetween the user arm heart ratecables and the console heart ratecable. Using a multimeter, verifycontinuity from the hand sensors tothe heart rate cable connector at theback of the console. Check fromhand sensor to frame ground toverify presence of shorts. Replaceany defective cables.

Inadequate contact withLifepulse sensors

Full contact must be maintained onall Lifepulse sensors in order toobtain a heart rate reading.

Faulty Lifepulse sensors Replace the sensors

No heart rate fromLifepulse sensors

Faulty console board Replace the console board


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Transmitter is incorrectlypositioned or is not makinggood contact with the body

Reposition the transmitter onthe chest. Moisten thetransmitter for better skincontact and a stronger signal.

User is out of monitoringrange

User must be within three feet(one meter) of the Polarreceiver.

Telemetry option turned off Verify in Diagnostics thatTelemetry is turned on.

Faulty connection betweenconsole and receiver

Verify that the Polar heart ratecable is properly connected.Using a multi-meter, verifycontinuity between the receiver

jack and the cable connector atthe console. Replace the cable ifnecessary.

Faulty receiver If possible, swap the receiverwith a known working unit.Replace the transmitter ifnecessary.

No heart rate readingusing Polar transmitter1

Faulty console board Replace the console board

Cross talk from anothertransmitter. Possibleinterference from otherelectronic devices

Position the cross-trainer atleast three feet (one meter)from other units withTelemetry.

Erratic heart rate usingthe Polar transmitter1

Faulty console board Replace the console board.

LCD backlight Reconnect the LCD touchscreen.Replace if necessary.

Faulty backlight powerinverter

Reconnect the backlightinverter. Replace if necessary.

LCD screen failure Reconnect the LCD touchscreen.Replace if necessary.

Screen is blank

Problem on the single boardcomputer

Replace the single boardcomputer.

Keypad malfunction Run the keypad test inDiagnostics.

Channels do not change

Defective interface PC board Replace the interface PC board

Keypad malfunction Run the keypad test inDiagnostics.

Sound does not change

Defective interface PC board Replace the interface PC board

1on Telemetry-equipped units only


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Faulty headphones Test with known goodheadphones. Replace headphones

if necessaryFaulty headphone jackassembly

Replace the headphone jackassembly

Faulty cable to headphonejack assembly

Replace the headphone jackassembly

Problem on the single boardcomputer

Replace the single boardcomputer

Problem on the interfaceboard

Replace the interface board

No sound

Incorrect air/cable setting Follow the setup procedures inthe Operation Manual

Incorrect air/cable setting Follow the setup procedures inthe Operation Manual

Faulty coax cable Replace coax cable

Unable to receive anychannels when using cable

Coax cable unplugged Check coax cable connection.

Incorrect air/cable setting Follow the setup procedures inthe Operation Manual.

Snow on the screen

Faulty coax cable Replace the coax cable.

LCD backlight Reconnect the LCD touchscreen.Replace if necessary.

Screen is dark

Faulty backlight powerinverter

Reconnect the backlight powerinverter. Replace if necessary.

Touchscreen failure Reconnect the touchscreen.Replace if necessary.

Screen does not respondto touch

Problem with the single boardcomputer

Replace the single boardcomputer.

Wrong buttons activatewhen the screen istouched

Touchscreen incorrectlycalibrated

In Diagnostics, calibrate thetouchscreen. Replace thetouchscreen if necessary.


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TROUBLESHOOTING GUIDE TESTING THE INVERTER BOARD

Special service tools required: multimeter

CAUTION! HIGH VOLTAGE AT CONNECTORS J2 AND J3!

1. Remove theentertainmentsystem consolefrom the unit.

2.

Remove the rearcover from the console assembly.

3.

Plug in the power supply and remote control to the console.

4. Press the Power On key on the remote control.

5.

Test No. 1:6. Place the red lead from the multi-meter onto Test Point 1 and the black lead

onto Test Point 3. Voltage should be 12 Vdc (+/- 0.5 V).

7.

Test No. 2:

8.

Place the red lead from the multi-meter onto Test Point 5 and the black leadonto Test Point 3. Voltage should be 12 Vdc (+/- 0.5V).

PROBLEM SOLUTION

No voltage on Test Point 1 Replace cable, remote, or main PC

Voltage present on Test Point 1 Replace the inverter board.

Voltage on Test Points 1 and 2 but no Replace the cable between the inverter

TEST POINT VOLTAGE DESCRIPTION PIN NUMBER

1 & 2 12 Vdc VIN 1 & 2

3 & 4 O Vdc Ground 3 & 4

5 12 Vdc Enable 5

5 0 Vdc Disable 5

6 Not used Not used 6, 7, 8

J3 J2

J11

2

3

4

5

6

Test Points


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TROUBLESHOOTING GUIDE TESTING THE POWER SUPPLY CABLE

Special service tools required: multi-meter

1.

Unscrew the RETAINING NUTsecuring the POWER CABLEPLUG.

2.

Remove the CABLE.

3.

Using a multi-meter, touch thered lead to the POSITIVE(center) area on the CABLE.

4.

Touch the black lead to theNEGATIVE area (the outside ofthe inner cable).

5.

The meter should read 12 Vdc.


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LCD DIAGNOSTICS


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Life Fitness Cross-Trainers 93X, 95Xe, and 95Xi with Quiet DriveLCD Diagnostics

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WELCOME SCREEN

The welcome screen appears immediately after power-up and when the unit is notin use. Touch the screen to bring up the workout selection screen.


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WORKOUT SELECTION SCREEN

To enter the systems option menu from the workout selection screen, hold downthe COOLDOWN key and double-tap the Life Fitnessicon.

After entering the system options, the main menu will appear. Refer to theoperators manual for more information about these programs.

Life Fitnessicon


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SYSTEM 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 to the workout selection screen.


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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 return to the system options main menu screen.


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SYSTEM DIAGNOSTICS

The System Diagnostics screen allows access to this information:

SYSTEM VOLTAGE system voltage (at the console)

ALTERNATOR VOLTAGE voltage output from the alternator

RPM pedal lever RPMs from the alternator

REED RPM pedal lever RPMs from the Reed switch

FIELD DUTY CYCLE %the percentage the alternator is beingactivated to produce a load (the higherthe number, the harder it is to pedal)

KEYPAD VALUEdisplays an acknowledgement when a keyis pressed on the console

LOAD DUTY CYCLE %controls the current Load Duty Cycle (canbe adjusted using the UP ARROW andDOWN ARROW keys)

REEDindicates whether the Reed switch isenabled or disabled (can be toggled bypressing the corresponding circle)

TEST ENGINEERINGthis test is for engineering purposes only(i.e., not applicable for servicing)

To exit system diagnostics, press the Main Menu button, then press the Exitbutton. To return to the system test menu, press the Back key.


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TEST ENGINEERING

All status windows on this screen should display off and should be changed only atthe direction of Life Fitness Customer Support.

Press the Back key to return to the system diagnostics screen.


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TELEMETRY TEST

The circles in the telemetry box indicate whether telemetry is enabled or

disabled. Telemetry can be toggled on and off by pressing the correspondingcircle. When telemetry is enabled, the users heart rate is displayed in the heartrate value window.

Press the Back key to return to the previous screen or the Main Menu key to returnto the units main menu.


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LIFEPULSETM TEST

Lifepulse can be tested manually. The system displays a hands on reading whenit detects the users hands on the Lifepulse sensors.

Detecting both left and right hands on conditions activates a timer (displayed inthe acquisition time window). The timer stops when a reading appears in the heartrate value window.

The gain and confidence level values are displayed in the appropriate windows.Gain indicates the strength of the heart rate signal the unit is receiving. A low

number indicates a strong signal, a high number indicates a weak signal.Confidence levels range from 0 to 9 (the higher the number, the higher theconfidence).



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CSAFE NETWORK TEST

This test will allow the user to verify that the cross-trainers connectivity featuresare functioning properly. Follow the on-screen instructions to perform the CSAFEloopback test. The responses Ready, Running, and either Pass or Fail willappear in the Test Log window.



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EEPROM TEST

Press the EEPROM Internal Test key to test the EEPROM on the single boardcomputer. Press the EEPROM External Test key to test the interface boardsEEPROM. In either test, a PASS message indicates a good EEPROM.

Press the Back key to return to the previous screen. Press the Main Menu to returnto the units main menu.


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INFORMATION MENU

The Information Menu screen allows access to this information:

STATISTICShistorical data regarding individual workout program usage andcritical system power levels

SOFTWARE VERSIONS information about current software versions

SYSTEM ERRORShistorical information on system errors encountered duringoperation

USAGE LOG historical information regarding pedal speeds and user weights

Press the Back key to return to the systems options main menu screen. Press theMain Menu key to return to the units main menu.


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INFORMATION STATISTICS

Statistics such as total hours of use and hours of use per program can be seen onthis screen.



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SOFTWARE VERSIONS

This screen displays the units current software versions and, where applicable,their corresponding Life Fitness part numbers.



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SYSTEM ERRORS

System errors that have been logged into the units memory can be seen on thisscreen.



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USAGE LOG REPORT

The usage log report allows the user to see detailed information regarding the

RPMs used at various levels.



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CONFIGURATION MENU

The Configuration Menu screen allows access to this information:

MANAGERsupervisory workoutparameter setup

MANUFACTURERcritical system parametersetup

TV television configuration

TOUCHSCREENCONFIGURATION

touchscreen proximitycalibration

Press the Back key to return to the systems options main menu screen. Press the

Main Menu key to return to the units main menu.


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MANAGERS CONFIGURATION

The Configuration Menu screen allows access to this information:

MAXIMUM WORKOUT

DURATION

Allows the manager to set the maximum workout time between1 and 99 minutes (the default is 60 minutes). Times can be

modified with the UP ARROW and DOWN ARROW keys.

STANDBY CONFIGURATONSets the amount of inactive time (from 0 to 24 hours) requiredbefore the LCD screen backlight goes off. The backlight comeson when the unit detects activity.

PROGRAM TIMEOUTSets the amount of time (from 20 to 255 seconds) the user cango without touching the screen before the console resets to theWelcome screen. The default is 60 seconds.

PAUSE TIMESets the amount of time (between 1 and 99 minutes) the unitcan be inactive before it reverts to the Welcome screen. Thedefault is 60 minutes.

UNITS Allows the user to choose between English and metric units.

LANGUAGEAllows the user to choose among eleven languages (English,Portuguese, Spanish, Dutch, Japanese, French, Italian, Chinese,Korean, Russian, and German)

CUSTOM MESSAGE SETUPAllows a custom message to be displayed on the Welcomescreen.



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CUSTOM MESSAGE SETUP

This section allows the user to display a custom message on the welcome screen.

To create or change a custom message: enter the Managers Configuration, EnableCustom Message, and Select Custom Message Setup. Enter the message using theon-screen keyboard shown in the illustration. The shift key is used to input capitalletters and special characters. The message will scroll across the top of thescreen, giving real-time feedback

To accept a custom message, press the Main Menu button.

To erase a custom message, press the Clear Message button.



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MANUFACTURERS CONFIGURATION MENU

This screen is available only to certified Life Fitness technicians.



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TV SETUP

The TV Setup mode allows adjustment of the screens brightness, contrast,saturation, and hue. TV format, antenna setup, and channel setup are also chosenhere.

To set up channels: In Channel Setup, select Auto, then press Start.

To delete an unwanted channel: In Channel Setup, select Manual, then use the CHDown and CH Up controls to change channels. Press Delete to delete a channel,then press Auto to return Channel Setup to Auto.

To restore a channel: In Channel Setup, press Manual, then use the CH Down andCH Up controls to change channels. Press Add to add a channel, then press Auto toreturn Channel Setup to Auto.

continued


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TV SETUP - CONTINUED

To adjust brightness, contrast, saturation, and hue: Use the corresponding LeftArrow and Right Arrow buttons. To return the unit to default settings, pressDefault1.

Use the Max Volume Setup key to adjust the units volume.


1The default settings are brightness, 180; contrast, 71; saturation, 64; and hue, 0.


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MAX VOLUME SETUP

The units volume is adjusted at this screen. Headphones must be used for thisfunction.

The upper set of arrow keys adjust the units volume capacity. This allowsmanagers to compensate for the ambient noise levels. The maximum volumereturns to this default after each workout.

The lower pair of arrow keys control the units current volume. The unit resets tothe mid-range volume corresponding to the maximum volume setup after eachsession.



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TOUCHSCREEN CONFIGURATION

Entry into this screen will allow the user to reconfigure the touchscreen. Thedisplay will show a blank screen with a plus sign in the middle as shown in theillustration above. Follow the directions that appear at the top of the screen,pressing on the plus sign as it moves to the four corners of the screen. If the userspress does not register, the procedure will have to be repeated. This configurationstate will be exited automatically when the screen has been calibrated

successfully.


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LED DIAGNOSTICS


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Life Fitness Cross-Trainers 93X, 95Xe, and 95Xi with Quiet DriveLED Diagnostics

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93X DISPLAY CONSOLE


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95XI DISPLAY CONSOLE


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MAP


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ENTRY LEVEL

Hold down the 5 key (on 95Xi units) or the Up Arrow key (on 93X units) thenpress the Clear key twice. Pressing the Up Arrow key repeatedly will cycle throughthe following:

CODE VERSION (example: CODE VER - XX)

CSAFE VERSION (example: CSAFE VER - X.XX.XX)

PART NUMBER (example: XXXX-XXXX-0000)

BOOT LOADER VERSION (example: BOOT VER - X)

Press Enter for access to the Optional Settings (see the diagnostics map on theprevious page). While pressing and holding COOL DOWN, press Enter for theTest/Service menu.

CODE VER - X.XX

C T


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TEST/SERVICE ALL LEDS AND KEYPAD TEST

On entry into this state, all the LEDs will turn on. Pressing any key except Start,Enter, or Clear will result in a beep. A character will also be displayed andrepeated across the message center.

Press Enter to advance to the next diagnostic state. Press Clear to return to theprevious state. Press Clear repeatedly to exit diagnostics.

XXXXXXXXXXXXXXXXXX

XXXXX


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TEST/SERVICE WALKING LED TEST

On entering this state, the LEDs in the Message Center and the Profile Window willdisplay an animated motion effect (walking LED).



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TEST/SERVICE MISCELLANEOUS TESTS 1

The field duty cycle being applied to the alternator is displayed in the heart ratewindow. This value ranges from 0 to 255. The alternator output voltage isdisplayed in the Distance window. The alternator RPM is displayed in the RPMwindow.

The load duty cycle applied to the alternator will be displayed in the Calorieswindow. The value ranges from 0 to 250 and can be adjusted using the Time Upand Time Down arrow keys (on model 95Xi) or the Up Arrow and Down Arrow keys(on the 93X).

Pressing the Aerobics Mode key will toggle the speaker on and off (not available onmodel 90X.)

continued

XXX XXX XX XXX


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TEST/SERVICE MISCELLANEOUS TESTS 1 - CONTINUED

Pressing the 5 key (with model 95Xi) will toggle the alternator on and off.



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TEST/SERVICE MISCELLANEOUS TESTS 2

The system voltage (Vsys) supplied to the console is displayed in the Heart Ratewindow. The reed switch RPM is displayed in the Distance window. The reed

switch RPM will not display when the alternator is running. The alternator RPM isdisplayed in the RPM window.

Pressing the 5 key (on model 95Xi) or the Down Arrow key (on model 93X) willdisplay the value of Vsys at startup (before the alternator is turned on). This isuseful because it will indicate the voltage of the 6 volt battery. Note: since thecurrent has gone through several voltage drops, this voltage will be lower thanwhen readings are taken at the batterys terminals.


XXX XX XX


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TEST/SERVICE PORT I/O TEST


RELAY FLD KICK


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59

TEST/SERVICE LIFEPULSE TEST

Upon entering this test, a heart will be displayed in the profile window along withtwo messages in the message center. The first message indicates the version

number of the Lifepulse software. The second indicates whether the Lifepulsecommunication system is on or off. (This system enables external communicationsfor Lifepulse development only and should be left off.) Following these messages,the unit will be ready for manual testing and will display the diagnosticinformation described below.

The left hands-on circuitry can be tested by grasping the left-hand pair ofelectrodes. When the sensor detects a hand in contact with both electrodes, anL is displayed in the profile window with the heart. Similarly, an R is displayedwhen a hand is detected by the right-hand electrodes.

continued

C-O G99


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60

TEST/SERVICE LIFEPULSE TEST - CONTINUED

Two timers begin counting when both left and right hands-on conditions occur.

The first timer, located on the upper console message center display, stops whenLifepulse computes and displays an initial peak detected heart rate. The secondtimer is located on the lower console display window. It will continue countinguntil Lifepulse can reliably determine a user heart rate. These timer readings areused for reference only.

The gain value of the heart rate signal is shown following the G in the messagecenter display window. Values range from 0 to 99. Gain values near either extremewould be considered undesirable. Values between 15 and 40 are considerednormal. Variations in that range would indicate whether the user is exercising or

standing still during the test.



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61

TEST/SERVICE CSAFE NETWORK TEST

The CSAFE network is tested in this state. This procedure will determine whetherthere is any communication from the network system:

1.

Make sure the network cable is plugged in.2.

Press the Cool Down key. This will reset the console and send a standard powerup message to the network. This is the same message the console sends everytime it is turned on (or any time it is used on self-powered products). Theconsole will display a RESETTING NETWORK message.

3.

If the network receives the CSAFE communication packet from the console andresponds with a configuration communication packet, the console will displayRECEIVING.

4. If the network does not respond to the console, a NOT CONNECTED messagewill be displayed. This means that the console has not received any valid CSAFE

communications from the network and indicates a problem with the network orthe network cable.


NOT CONNECTED


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62

TEST/SERVICE EEPROM TEST

This diagnostic state tests the display console EEPROM by reading, writing, andreplacing all used locations in the EEPROM. The location being tested will be

displayed in the message center. Pressing the Down Arrow will initiate the EEPROMtest. If the test is completed successfully, the message EEPROM GOOD willappear. If the test fails, EEPROM BAD AT ## will display with the faulty location.


EEPROM TEST -


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63

TEST SERVICE TELEMETRY ENABLE/DISABLE

TELEMETRY can be turned on and off in this state (the default state is on). If atelemetry heart rate can be detected, it will be displayed when telemetry is on.

The Down Arrow will turn telemetry off. The Up Arrow will turn it on and display aheart shape in the program profile window.

The Enter key LED indicates when the value is at the default (on) setting. Thisvalue is stored in EEPROM and is kept when the unit is turned off.


TELEMETRY ON


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64

TEST/SERVICE LANGUAGE

One of nine languages (English, German, French, Italian, Japanese, Dutch, Turkish,Spanish, or Portuguese) can be selected in this state. Pressing the Up Arrow and

Down Arrow keys cycle through the choices. The Enter key LED indicates when thelanguage is set to the default (English). This value is stored in EEPROM and is keptwhen the unit is turned off.

This is the final diagnostic state in Test/Service. Press Clear to return to theprevious state. Press Clear repeatedly to exit diagnostics.

LANG . = ENGLISH


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65

OPTIONAL SETTINGS MAX PROGRAM DURATION

The maximum program duration can be adjusted from 10 to 99 minutes in thisstate.

Pressing the Down Arrow key will decrease the value in 1-minute increments. TheUp Arrow key will increase it in 1-minute increments. Both keys auto-repeat if helddown.

The Enter key LED indicates when the value is at the default (60 minutes). Thisvalue is stored in EEPROM and is kept when the unit is not in use.


MAX DURATION 60


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66

OPTIONAL SETTINGS ENGLISH/METRIC UNITS

English or metric units can be chosen in this state.

The Down Arrow key selects metric units, the Up Arrow key selects English units.

The Enter key LED indicates when the default setting (English units) is on. Thisvalue is stored in EEPROM and is kept when the unit is turned off.


ENGLISH UNITS


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67

OPTIONAL SETTINGS WATTS DISPLAY ENABLE/DISABLE

When this option is enabled, the message center displays the watts equivalent ofthe workload. This information is displayed only after level changes.

The Down Arrow turns off the watts program. The Up Arrow turns it on.

The Enter key LED indicates when the default (watts on) setting has been chosen.This value is stored in EEPROM and is kept when the unit is turned off.


WATT DISPLAY ON


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69

OPTIONAL SETTINGS CAL/HR DISPLAY ENABLE/DISABLE

When this option is enabled, the message center displays the workloads calories-per-hour equivalent. This information is displayed only after level changes.

The Down Arrow turns off the CAL/HR program. The Up Arrow turns it on.

The Enter key LED indicates when the default (on) setting has been chosen. Thisvalue is stored in EEPROM and is kept when the unit is turned off.


CAL/H DISP. ON


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70

AVAILABLE PROGRAMS

HOUR1

DIST2

X-REV

QUICK START

HILL

HEART HILL

RANDOM

HEART INT

MANUAL

HEART EXT

PRE SET

FAT

CARDIOCUSTOM

AEROBICS

HOUR = XXX

OPTIONAL SETTINGS TOTAL HOURS AND STATISTICS

This state displays total hours.

Statistics can be displayed by pressing theUp Arrow and Down Arrow keys. The UpArrow key allows scrolling through theavailable programs and indicates the numberof times each has been chosen. The DownArrow key backs through the same list(shown in the table on the right).

Press Enter to advance to the next

diagnostic state. Press Clear to return to theprevious state. Press Clear repeatedly toexit diagnostics.

1total hours on the console2total distance on the console, in miles


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71

OPTIONAL SETTINGS ENTERTAINMENT CONTROLS ON/OFF

The Up Arrow and Down Arrow keys will turn on and off the channel and volumecontrols for third-party entertainment systems (such as Cardio Theater). Thedefault setting is off.

Note: this does not turn on or off the power to the C-SAFE port.


ENTERTAIN OFF


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72

OPTIONAL SETTINGS PHOTO SHOOT

In Photo Shoot mode, the data displayed in the Message Center is non-functionaland is intended only to simulate values for photographic sessions.

This is the final diagnostic state. Press Clear to return to the previous state. PressClear repeatedly to exit diagnostics.

135 1.09 62 205

17:44


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HOW TO


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How To

75

HOW TO REPLACE THE CONSOLE SUPPORT COVER

Special service tools required: none

1. Remove the console

support cap by squeezingthe sides and pulling itaway from the consolesupport.

2. Remove the two Phillipsscrews securing theconsole support cover tothe console support.

3. Reverse steps 1 and 2 toinstall the new consolesupport cover.


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How To

76

HOW TO REPLACE THE CONSOLE ASSEMBLY


1. Remove the console support

cover (see How To on page75).

2. Remove the four Phillips screwssecuring the console to theconsole support

3. Disconnect the main cable andthe heart rate cable, if present,from the rear of the console.

4. Reverse steps 1 through 3 to

install the new console.


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How To

77

HOW TO REPLACE THE ACCESSORY TRAY


1. Remove the console support

cover (see How To onpage 75).

2. Remove the console (seeHow To on page 76).

3. Remove the two Phillipsscrews securing theaccessory tray to theconsole support.

4. Lift the accessory tray upand out of the main upright.

5. Reverse steps 1 through 4 toinstall the new accessorytray.


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How To

78

HOW TO REPLACE THE CONSOLE SUPPORT BRACKET


1. Remove the console support cover

(see How To on page 75).

2. Remove the console (see HowTo on page 76).

3. Remove the accessory tray (seeHow To... on page 77).

4. Remove the six Allen boltssecuring the console support tothe main upright.


install the new console supportbracket.


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How To

79

HOW TO REPLACE THE BULLHORNS


1. Remove the Phillips screw

securing the bullhorn cover tothe bullhorn.

2. Remove the two Torx boltssecuring the bullhorn to thedeadshaft.

3. Reverse steps 1 and 2 toinstall the new bullhorns.


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How To

80

HOW TO REPLACE THE DEADSHAFT COVERS


1. Remove the two screws securing

the deadshaft covers to eachother.

2. Use the same screws to installthe new deadshaft covers.


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How To

81

HOW TO REPLACE THE HANDLEBARS


1. Remove the outside deadshaft

covers (see How To... onpage 80).

2. Remove the three Torx boltssecuring the handlbar to theend of the deadshaft.

3. Disconnect the heart ratecable, if it is present.

4. Reverse steps 1 through 3 toinstall the new handlebars.


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How To

82

HOW TO REPLACE THE LIFEPULSE SENSORS


1. Remove the two screws securing

the Lifepulse sensors to thehandlebar.

2. Disconnect the heart rate cablefrom the Lifepulse sensors.

3. Reverse steps 1 and 2 to installthe new Lifepulse sensors.


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How To

83

HOW TO REPLACE THE FRONT FRAME COVER


1. Remove the two screws securing the front frame cover to the frame.

2. Slide the front frame coverforward until it is free of theladder frame cover.

3. Reverse steps 1 and 2 toinstall the new front framecover.


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How To

84

HOW TO REPLACE THE MAIN SHROUD ASSEMBLY


1. Remove the four Phillips screws

(two on each side) that securethe main shroud assembly to thedrive frame assembly.

2. Remove the main shroudassembly by lifting it straight up.

3. Reverse steps 1 and 2 to installthe new main shroud assembly.


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How To

85

HOW TO REPLACE THE LADDER FRAME COVER


1. Remove the front frame cover (see How To... on page 83).

2. Remove the main shroudassembly (see How To... onpage 84).

3. Remove the two Phillipsscrews securing the ladderframe cover to the ladderframe.

4. Remove the ladder framecover.


install the new ladder framecover.


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How To

86

HOW TO REPLACE THE CONSOLE CABLE ASSEMBLY


1. Remove the front frame cover

(see How To... on page 83).

2. Remove the main shroud assembly(see How To... on page 84).

3. Remove the ladder frame cover(see How To... on page 85).

4. Remove the console support cover(see How To on page 75).

5. Remove the console assembly (seeHow To... on page 76).

6. Disconnect the console cableassembly from the console andthe power control board.

7. Remove the cable ties that securethe console cable assembly to theladder frame.

8. Fasten one end of the new cableto one end of the old cable beforeremoving it from the unit. (Thiswill enable you to route the newcable through the upright moreeasily.)

9. Route the new cable through theupright and reverse steps 1 through 7 to complete the console cable assemblyinstallation.


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How To

87

HOW TO REPLACE THE LOWER SHROUD PANELS


1.

Remove the four Phillipsscrews securing the lowershroud panels to the drivefame assembly. There are twoscrews for each panel.

2. Use the same screws to installthe new lower shroud panels.make sure the main shroudassembly and lower shroudpanels fit into each other.


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How To

88

HOW TO REPLACE THE OUTER LEVER JOINT COVER AND ROCKER ARMCOVER


1. Remove the Phillips screw securing the outer rocker cover to the inner rockercover.

2. Remove the Allen boltsecuring the outer pedal jointcover to the pedal and rockershaft.

3. Reverse steps 1 through 3 toinstall the new outer pedaljoint cover and rocker armcover.


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How To

89

HOW TO REPLACE THE INNER LEVER JOINT COVER AND INNER ROCKERARM COVER


1.

Remove the outer lever jointand rocker arm covers (seeHow To... on page 88).

2. Remove the two set screwssecuring the pedal/rockershaft to the pedal leverassembly and slide the pedalrocker shaft out of both thepedal lever and rocker arm.

3.

Carefully separate the pedal

lever from the rocker arm.The inner covers will remainon each assembly.

4.

Remove the inner pedal levercover and inner rocker armcover.

5.

Reverse steps 1 through 5 toinstall the new inner pedallever cover and inner rockerarm cover.

Note: Each cover has a tab on itwhich must be inserted intoeither the square hole in therocker arm or the pedal leverassembly. Once the tab has beenengaged, seat the cover andcomplete the installation.


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How To

90

HOW TO REPLACE THE ROCKER ARM


1.

Remove the outer

deadshaft covers (seeHow To... on page 80).

2.

Remove the handlebar(see How To... on page81).

3.

Remove the outer leverjoint cover and rocker armcover (see How To... onpage 88).

4.

Remove the retaining ring

and washer securing therocker arm to thedeadshaft

5.

Remove the set screwssecuring the pedal/rockershaft to the pedal lever,then slide the pedalrocker shaft out of boththe pedal lever and rockerarm.

6.

Carefully slide the rockerarm off the deadshaft.

7.

Reverse steps 1 through 6to install the new rockerarm.


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How To

91

HOW TO REPLACE THE OUTER LINK COVER


1.

Remove the main shrouds

(see How To... on page84).

2.

Remove the six Phillipsscrews (three at the top,three at the bottom) thatsecure the outer link coverto the inner link cover.

3.

Reverse steps 1 and 2 toinstall the new outer linkcover.


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How To

92

HOW TO REPLACE THE PEDAL LEVER ASSEMBLY


1.

Remove the main shroud assembly (see How To... on page 84).

2.

Remove the outer link cover (see How To on page 91).

3.

Remove the outer lever joint and rocker covers (see How To on page 88).

4.

Remove the set screws securing the pedal/rocker shaft to the pedal arm.5.

Slide the pedal/rocker shaft out of both the pedal lever assembly and therocker arm.

6. Remove the bolt securing the crank extension to the Crankarm.

7.

Remove the set screws that secure the shaft collar to the Crankarm andremove shaft collar.

8.

Slide the pedal lever assembly off the crankshaft.

9.

Reverse steps 1 through 8 to install the new pedal lever assembly.


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How To

93

HOW TO REPLACE THE CONTROL LINK ASSEMBLY


1.


2. Remove the outer link cover (see How To... on page 91).

3.

Remove the hex nut securing the front end of the control link assembly to thepedal lever.

4.

Remove the crank extension mounting bolt that secures the rear of the controllink assembly.

5. Reverse steps 1 through 4 to install the new control link assembly.

Note: apply Loctite 242 to the Torx bolts and nuts that secure the control link andcrank extension to the unit.


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How To

94

HOW TO REPLACE THE CRANKARM COVER


1.


2.

Remove the outer link cover (see How To... on page 91).

3.

Remove the outer lever joint cover (see How To... on page 88).

4.

Remove the pedal lever assembly (see How To... on page 92).5.

Remove the Allen bolts securing the crankarm cover to the crankarm.

6. Reverse steps 1 through 5 to install the new Crankarm cover.


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How To

95

HOW TO REPLACE THE MAIN DRIVE BELT


1.

Remove the main shroud assembly (see How To... on page 84).2.

Remove the left outer link cover (see How To... on page 91).

3.

Remove the outer lever joint and rocker arm cover on the left pedal leverassembly (see How To... on page 88).

4.

Remove the left pedal lever assembly (see How To... on page 92).

5.

Remove the left crankarm cover (see How To... on page 94).

6.

Walk the main drive belt off the crossover shaft and remove the main drivebelt from the unit.

7.

Install the new belt around the crossover shaft first, then walk it onto the

crank pulley.

8. Reverse steps 1 through 5 to complete the replacement.

Main Drive Belt

Crossover ShaftCrank Pulley

Left Crank Arm

Weld Assembly


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How To

96

Mounting Plate

HOW TO REPLACE THE BATTERY


1.

Remove the main shroud

assembly (see How To... onpage 84).

2.

Disconnect the red and blackwires from the battery.

3.

Remove the two screws thatsecure the battery to themounting plate.

4. Reverse steps 1 through 3 toinstall the new battery.


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How To

97

Mounting Plate

HOW TO REPLACE THE REED SWITCH CABLE ASSEMBLY


1.

Remove the main shroud assembly

(see How To... on page 84).2.

Disconnect the reed switch cablefrom the power control board.

3. Remove the two screws securingthe reed switch to the mountingplate.

4.

Reverse steps 1 through 3 tocomplete the installation.


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How To

98

Mounting Plate

HOW TO REPLACE THE POWER CONTROL BOARD


1. Remove the main shroud


2.

Tag and identify wiring at thepower control board.

3.

Disconnect the wiring from thepower control board.

4.

Remove the four screws thatsecure the power control boardto the mounting plate.

5.

Use the same four screws toinstall the new power controlboard.

6. Connect the wiring to the newpower control board.

7.

Reinstall the main shroudassembly.


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How To

99

HOW TO REPLACE THE ALTERNATOR BELT


1.

Remove the main shroud assembly (see How To... on page 84).2.

Walk the alternator belt off the Poly-V pulley and remove the belt.

3.

Place the new alternator belt around the alternator pulley and slowly walk thebelt onto the Poly-V pulley until it is centered.

4.

Reinstall the Main shroud assembly.

Alternator

Poly-V Pulley

Alternator

Belt


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How To

100

Crossover

Shaft

Set Screws

Poly-V Pulley

Machine

Key

Flat Washer

and Screw

HOW TO REPLACE THE POLY-V PULLEY


1.



2.

Remove the right lower shroudpanel (see How To... on page87).

3.

Walk the alternator belt off thePoly-V pulley and remove thebelt.

4.

Remove the Allen screw andwasher securing the Poly-V

pulley to the crossover shaft.5. Remove the set screws securing

the Poly-V pulley to themachine key.

6. Slide the Poly-V pulley off the crossover shaft

7.

Reverse steps 1 through 6 to install the new Poly-V pulley.

Note: apply Loctite 242 to all screws securing the Poly-V pulley to the crossovershaft.


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How To

101

Alternator

Poly-VPulley

AlternatorMounting

Nut andBolts

HOW TO REPLACE THE ALTERNATOR


1.


assembly (see How To...on page 84).

2.

Walk the alternator belt offthe Poly-V pulley.

3.

Remove the alternator belt.

4.

Note where each wireterminates on the alternator.

5.

Disconnect all wires attachedto the alternator.

6.

Remove the hex nut andmounting bolts securing theAlternator to the drivemodule.

7.

Install the new alternator inreverse order ensuring thatall wires are connected tothe proper terminals.


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How To

102

HOW TO REPLACE THE PEDAL


1.

Remove the four Torx bolts securing the pedal to the pedal lever assembly.

2.

Use the same bolts to install the new pedal.


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How To

103

Resistor Mounting

Rods and washers

Resistors

Resistor Mounting

Bracket screws

Wire screws

Resistor Mounting

Bracket

HOW TO REPLACE THE RESISTOR BRACKET ASSEMBLY


1.



2.

Remove the lower shroudpanels (see How To... onpage 87).

3.

Disconnect all wires attachedto the alternator. Note whereeach wire terminates on thealternator.

4.

Disconnect connector end of

cable from power controlboard at P2. A new cable isincluded with the new resistorbracket assembly and isalready connected to theresistors.

5.

Remove two screws securingresistor mounting bracket to frame.

6.

Reverse steps 1 through 5 to install the new resistors bracket assembly.


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How To

104

HOW TO REPLACE THE MAGNET AND STANDOFF ASSEMBLY


1.

Remove the main shroud assembly

(see How To... on page 84).2.

Remove the left outer link cover(see How To... on page 91).

3. Remove the left pedal leverassembly (see How To... on page92).

4.

Remove the crankarm cover (seeHow To... on page 94).

5.

Remove the screw securing themagnet/standoff assembly to the

main drive pulley.

6.

Reverse steps 1 through 5 to installthe new magnet/standoff assembly.


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How To

105

HOW TO REPLACE THE RIGHT CRANKARM


1.


2.

Remove the right outer link cover (see How To... on page 91).

3.

Remove the right pedal lever assembly (see How To... on page 92).

4.

Remove the right crankarm cover (see How To... on page 94).

5.

Loosen the hex bolt and nut securing the right Crankarm to thecrankshaft/pulley assembly.

6.

Loosen the set screw securing the machine key to the crankshaft/pulleyassembly.

7.

Slide the right Crankarm off the crankshaft /pulley assembly.

8.

Reverse steps 1 through 7 to install the new right Crankarm.


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How To

106

HOW TO REPLACE THE LEFT CRANKARM/PULLEY ASSEMBLY


1.


2.

Remove the outer link covers (see How To... on page 91).3. Remove the pedal lever assemblies (see How To... on page 92).

4. Remove the left crankarm cover (see How To... on page 94).

5.

Walk the main drive belt off the crank pulley.

6. Loosen the bolt, nut and set screw securing the left crankarm/pulley assemblyto the crankshaft.

7.

Remove the left Crankarm/pulley assembly by sliding off of the left end ofcrankshaft.

8.

Remove the four Allen bolts that connect the crankshaft plate, crank pulley,and left Crankarm weld assembly together.

9.

Replace left Crankarm, drive pulley or both components at this time.

10.

Reverse steps 1 through 8 to install the new crankshaft and pulley assembly

Left Crank Arm/Pulley

Assembly

Crankshaft


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How To

107

HOW TO REPLACE THE PEDAL/ROCKER SHAFT BEARINGS

Special service tools required: bearing tool kit

1. Remove the front and reardeadshaft covers.

2. Remove the three bolts securing thehandlebar to the rocker arm andremove the handlebar.

3. If so equipped, disconnect the heartrate cable.

4. Remove the retaining ring andwasher that secures the rocker armto the deadshaft.

5. Remove the outer pedal lever coverand outer rocker arm cover.

6. Remove the two Allen screws thatsecure the pedal lever to thepedal/rocker shaft and remove thepedal.

7. Remove the rocker arm unit (discardthe pedal/rocker shaft).

continued


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How To

108

HOW TO REPLACE THE PEDAL/ROCKER SHAFT BEARINGS CONTINUED

8.

Install the bearing puller on the

rocker arm as shown.

9.

Press the needle bearings out byrotating the hex nut clockwiseuntil the bearings drop into thepuller.

10.

Once the bearings are out of therocker arm, disassemble thepuller assembly and discard thebearings.

11.

Clean the housing beforeinstalling the new bearings.

continued


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How To

109

HOW TO REPLACE THE PEDAL/ROCKER SHAFT BEARINGS CONTINUED

12.

Position the new needle bearings

and bearing tool as shown. Make sure thebearings are squared and aligned with thebearing markings (the markings should befacing outward).

13.Tighten the hex nut. Hold the spacer ifit turns with the hex nut.

14.Continue pressing in the new needlebearings until the thrust washer andhub stop against the rocker arm

housing.

15.

Reassemble the shaft, rocker arm,handlebar assembly, and covers.

continued


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How To

110

HOW TO REPLACE THE CROSSOVER SHAFT AND/OR CROSSOVERBEARINGS

1.

Remove the screws securing the

main shrouds to the frame (twoscrews per shroud).

2. Remove the screws securing thelower shroud panels to the frame(two screws per shroud).

continued


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How To

111

HOW TO REPLACE THE CROSSOVER SHAFT AND/OR CROSSOVERBEARINGS - CONTINUED

3.

Walk the alternator belt off the alternator and Poly-V pulley.

4.

Walk the main drive belt off the crank pulley and crossover pulley.

5.

Remove the Torx screw, washer and set screws securing the Poly-V pulley tothe crossover shaft

6. Loosen the set screws securing the right side crossover bearing to the crossovershaft.

7.

Remove the nuts and bolts securing the bearing flanges to the drive moduleand remove right side crossover bearing and flanges.

8.

Slide the crossover shaft out of the users left side of the drive module andremove left bearing from crossover shaft by loosening the set screws on thebearing.

Crossover

Pulley and

ShaftSet Screws (2)

Key

Poly-V Pulley

Washer

Screw

Alternator Belt

Drive

Belt

Thrust

Washer(2)

continued


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How To

112


9.

Discard the old hardware, bearing flanges, bearings and crossover shaft ifnecessary.

Note: It is recommended that the flanges be replaced when replacing bearings.

10.

Position two new bearing flanges around one new bearing and loosely mountthem to the users right side of the drive module using new nuts and bolts.The holes in the flanges should line up with the holes in the drive module.The bearing set screws should face towards the inside of the drive module

frame.

11. Slide the remaining new bearing onto either the existing crossover shaft or anew crossover shaft until it is flush against the pulley on the left side of thecrossover shaft. With the bearing set screws facing toward the inside of thedrive module tighten the bearing set screws.

Bearing Flanges

Bearing with set

screws facing outward(left and right side)

Bearing with setscrews facing inward(left and right side)

Retaining Ringon Drive Shaft

Bearing FlangeMounting hardware

CrossoverShaft Torque Flange

hardware to18-20 ft. Lbs.

continued


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How To

113


12.

Position the remaining two bearingflanges around the bearing mounted to

the crossover shaft. Slide thisassembly through the left side of thedrive module and then through theright side bearing.

13. Loosely secure the left side bearing tothe drive module using new nuts andbolts. Move the crossover shaft up anddown to ensure proper seating ofbearing flanges around bearings andthen hand tighten nuts.

14. With all parts and hardware in positionslowly tighten the mounting hardware.Start with the upper right side nutfollowed by the lower right side nut andthen the upper left side nut and lastlythe lower left side nut. Tighten thesenuts in the same manner you would lugnuts on a tire (a little at a time on eachnut), constantly turning the crossovershaft to ensure that it turns freely.

15. If the crossover shaft turns freelycontinue to tighten the nuts to 18-20 ft.lbs. If the it binds, loosen the bearingflange hardware and adjust the positionof the bearing in the bearing flanges bymoving the crossover shaft up and downuntil the crossover shaft turns freely and then tighten.

Documents

LifeFitness CT 90X 93X 95Xi 95Xe Service Manual