Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers Service Manual

Models 8500, 9100, and 9500HR
Total Body Cross-Trainers with Rear Drive System
Customer Support Services
SERVICE MANUAL
Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers
INTRODUCTION
HOW TO USE THIS SERVICE MANUAL AND CONTACT CUSTOMER SUPPORT SERVICES
This service manual is applicable to Cross-Trainer Models CT8500, CT9100, and CT9500HR. Note: Information represents
typical configuration and may differ slightly from actual equipment. The Service Manual provides recommendations for
safe and efficient approaches to problem situations. This manual is separated into six sections.
INTRODUCTION
THEORY OF OPERATION
TERMINOLOGY
TABLE OF CONTENTS
Section I
q TROUBLESHOOTING GUIDES
Section II
q DIAGNOSTIC TESTS
Section III
q "How To..." SERVICE AND REPAIR GUIDES
Section IV
q ELECTRONICS OVERVIEW
q WIRING BLOCK DIAGRAMS
Section V
q PARTS IDENTIFICATION
Section VI
q MISCELLANEOUS INFORMATION
Refer to TABLE OF CONTENTS for section topics.
When an operating problem occurs, refer to troubleshooting guides and diagnostic tests in an attempt to isolate the cause.
When applicable, guides and tests are listed by symptom followed with suggestions of probable cause(s).
Once you have pinpointed the source of the problem, refer to "How To..." guides for recommended repair procedures. "How
To..." sub-sections are organized by replaceable part or assembly name. For convenience, sub-section lists recommended
Tools Required to complete each specific function.
Refer to the PARTS IDENTIFICATION section to identify proper name and number of part to order for repair of equipment.
A reproducible telefacsimile order claim form is provided in COMMUNICATING BY TELEFACSIMILE for convenient ordering of
service parts.
To order, contact Life Fitness Customer Support Services.
Via telefacsimile - 24 hrs. /day, 7 days/week.
Via telephone - Monday through Friday from 8:00 AM to 7:00 PM ( C.S.T.).
To speed Life Fitness Customer Support Services response to your needs, please be prepared to provide the following
information to the phone technician.
1. Model number
2. Serial number consists of 3 letters and 6 numbers
3. Symptom of problem
4. Part name and number to order (if known)
Before installing a part, review "How To..." and follow the step by step procedures recommended to install the part safely and
efficiently. If you have questions or comments, please telephone, FAX or write us. We are:
LIFE FITNESS - CUSTOMER SUPPORT SERVICES

10601 Belmont Avenue; Franklin Park, IL 60131; U.S.A.
Telephone: 847.451.0036 or Toll Free 800.351.3737
FAX: 847.288.3702 or Toll Free 800.216.8893

THEORY OF OPERATION
The electronic system on the rear-drive crosstrainer is made up of three main functional blocks: 1) Console, 2) HR
telemetry, and 3) Alternator, Power Control Board, and Load. In addition, the 9500 model has Lifepulse contact HR.
The following is a description of each functional block:
CONSOLE
The system voltage (6-7.5Vdc) enters on connector P2 pin 1 and is used to power the LEDs and provide a supply
voltage for the 5V-regulator circuitry used to power the microprocessor section.
The Keypad entry (users input), Lifepulse (9500HR only), and Telemetry are all processed by the microprocessor.
The console outputs a PWM signal to the power control board to control the duty cycle of the load.
ALTERNATOR, POWER CONTROL BOARD, AND LOAD
Using the PWM signal from the console, the power control board switches the current on and off at the load via
Q1. The control board also regulates the alternator voltage using the U1 comparitors. Q3 and Q9 are used to
sense the reed switch actuation (autostart feature).
POLAR
HR telemetry is implemented via a Polar receiver located in the rocker arm shroud at the front of the unit. The
Polar receiver connects to the console at connector P7.
LIFEPULSE (9500 ONLY)
The handlebar electrodes connect to the console board at connector P9. Pins 1 and 4 are signal, pins 2 and 3 are
circuit reference.

TERMINOLOGY
The following words and acronyms are commonly referred to throughout this manual. Take time to familiarize yourself
with them.
Connectors
Electrical plugs used to connect wiring into electrical component.
Display Console
Board
Electronic board for making settings and monitoring physical output.
DSP
Disgital system processing.
EEPROM
Electrically errasible programmable read only memory.
EEROM
Electrically errasible 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.
PCB
Power control board regulates voltage to 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.
RPM
Revolutions per minute describes the amount of times something turns within a minute of
time.
TABLE OF CONTENTS
SECTION I
TROUBLESHOOTING GUIDES
PAGE
GRINDING, RUBBING, KNOCKING NOISE..................................................................... 2
DRIVE BELT SLIPPING ................................................................................................ 3
UPPER ARMS LOOSE................................................................................................. 3
PLAY IN PEDAL LEVER............................................................................................... 3
NO LOAD .................................................................................................................... 3
NO LEDS ON DISPLAY ................................................................................................ 3
ALTERNATOR BELT SLIPPING..................................................................................... 4
NO HEART RATE OR ERRATIC HEART RATE ............................................................... 4
NO LEDS or RANDOM LEDS LIT................................................................................... 5
NO RPM...................................................................................................................... 5
AUTO START FAILURE ................................................................................................ 5
NOTES........................................................................................................................ 6
SECTION II
DIAGNOSTIC MODES
DISPLAY CONSOLES .................................................................................................. 2
ENTERING DIAGNOSTIC STATES 1-17 ......................................................................... 3
DIAGNOSTIC STATE 1: LEDS AND KEYPAD TEST........................................................ 4
DIAGNOSTIC STATE 2: INDIVIDUAL LED TEST.............................................................. 5
DIAGNOSTIC STATE 3: CODE VERSION/RPM/HEART RATE/LDC TESTS....................... 6
DIAGNOSTIC STATE 3: CODE VERSION/RPM/NETWORKING/LDC TESTS
(DISPLAY LOCK EQUIPPED MODEL ONLY)......................................... 7
DIAGNOSTIC STATE 4: FIELD/ALTERNATOR REGULATOR TEST................................ 8
DIAGNOSTIC STATE 5: PROGRAM VERSION AND NETWORKING TEST ....................... 9
DIAGNOSTIC STATE 5: LIFEPULSE TEST
DIAGNOSTIC STATE 6: MAXIMUM WORKOUT DURATION ............................................. 11
DIAGNOSTIC STATE 7: TELEMETRY ON/OFF............................................................... 12
DIAGNOSTIC STATE 8: ENGLISH / METRIC UNITS ........................................................ 13
DIAGNOSTIC STATE 9: POWER SUPPLY TYPE ........................................................... 14
DIAGNOSTIC STATE 10: SHUTDOWN TIME .................................................................. 15
DIAGNOSTIC STATE 11: PROGRAM TIME .................................................................... 16
DIAGNOSTIC STATE 12: STATISTICS............................................................................ 17
DIAGNOSTIC STATE 13: METS ENABLE / DISABLE ...................................................... 18
DIAGNOSTIC STATE 14: KEYPAD SELECTION ............................................................. 19
DIAGNOSTIC STATE 15: TOGGLE ENABLE / DISABLE.................................................. 20
DIAGNOSTIC STATE 16: PHOTOSHOOT....................................................................... 21
DIAGNOSTIC STATE 16: LANQUAGE CONFIGURATION
DIAGNOSTIC STATE 17: PHOTOSHOOT
NOTES........................................................................................................................ 24
TABLE OF CONTENTS Continued
SECTION III
HOW TO...REPLACE THE:
DISPLAY CONSOLE .................................................................................................... 2
ACCESSORY TRAY (OPTIONAL ON CT8500) ................................................................ 3
DISPLAY CONSOLE SUPPORT ASSEMBLY ................................................................. 4
REAR COVERS ........................................................................................................... 5
CRANKARM ROLLER ASSEMBLY AND COVER ........................................................... 6
CRANKARM ASSEMBLY ............................................................................................. 7
DRIVE BELT AND ALTERNATOR BELT......................................................................... 8
POWER CONTROL BOARD ASSEMBLY....................................................................... 9
ALTERNATOR.............................................................................................................. 10
ALTERNATOR BELT..................................................................................................... 11
PEDAL LEVER ASSEMBLY ......................................................................................... 12
ROCKER ARMS........................................................................................................... 13
TIE ROD ...................................................................................................................... 14
CRANKSHAFT PULLEY ASSEMBLY............................................................................. 15
INTERMEDIATE PULLEY.............................................................................................. 16
LOAD RESISTORS....................................................................................................... 17
USER ARMS ............................................................................................................... 18
POLAR RECEIVER ...................................................................................................... 19
MONOCOLUMN COVER............................................................................................... 20
FRAME COVER........................................................................................................... 21
FRONT COVER............................................................................................................ 22
BATTERY .................................................................................................................... 23
REAR WHEELS AND AXLE .......................................................................................... 24
ENDCAPS ................................................................................................................... 25
PEDAL ....................................................................................................................... 26
SET JUMPERS ON CSAFE CARD ................................................................................ 27
NOTES........................................................................................................................ 28
SECTION IV
ELECTRONICS OVERVIEW / WIRING DIAGRAM
DISPLAY CONSOLE BOARD........................................................................................ 2
POWER CONTROL BOARD.......................................................................................... 4
ALTERNATOR.............................................................................................................. 5
WIRING BLOCK DIAGRAM ........................................................................................... 6
NOTES........................................................................................................................ 7
TABLE OF CONTENTS Continued
SECTION V
PARTS IDENTIFICATION
MODEL IDENTIFICATION and SERIAL NUMBER LOCATION ........................................... 2
CT 8500....................................................................................................................... 3
CT 9100....................................................................................................................... 5
CT 9500 - 15 ................................................................................................................ 7
CT 9500 - 17 ................................................................................................................ 9
NOTES........................................................................................................................ 11
SECTION VI
MISCELLANEOUS INFORMATION
PREVENTIVE MAINTENANCE TIPS .............................................................................. 2
INSTALLATION INSTRUCTIONS .................................................................................... 3
UNPACKING INSTRUCTIONS........................................................................................ 9
COMMUNICATING BY FAX........................................................................................... 10
NOTES........................................................................................................................ 12
2000 Life Fitness, a division of Brunswick Corporation. All rights reserved. Life Fitness, Lifecycle, and Lifepulse are registered trademarks, and 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 express written consent of Life Fitness or the corresponding companies is forbidden.
M051-00K61-B014
07/00
Section I
Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers
SECTION I
TROUBLESHOOTING
GUIDES
Malfunction
Grinding, rubbing, knocking noises
when pedal levers rotate under
load.
Probable Cause
Corrective Action
Pulleys misaligned.
Loosen the pillow block bearings,

realign the pulleys, and retighten the
pillow block bearings.
Dirt build up in pedal tracks.
Clean and remove dirt build up.
Rear roller wheels frozen.
Clean and lubricate with non

detergent oil.
Link cover contacting rear cover.
Reposition rear cover(s) or replace.

Check that the inner link cover
mounting screws are properly
installed.
Excessive disk wobble.
Make sure no weld interference

occurs between the crankarm and
the disk cover.
Ensure that the crankshaft is flush
with the crankarm and check for
proper alignment. See How To.
Faulty intermediate shaft assembly.
Replace intermediate shaft assy.
Faulty pillow block.
Replace pillow blocks on crankshaft.
Alternator.
Relieve tension on alternator, spin

flywheel for smoothness. If
thumping occurs, faulty alternator.
Replace alternator.
Bearings at pivot points are out of

position or dirty.
Clean all sleeves in the linkage pivot

areas and lubricate with non
detergent oil.
Setscrews or crankarm bolt in

crankarm assembly are loose.
Loosen setscrew and clamping

screw in crankarm assembly. Apply
blue Loctite (242) on screw threads.
Tighten setscrew first to set keyway,
then tighten clamping screw.
Crankarm bolt requires no Loctite.
Small extension arm bolt loose.
Replace small extension arm kit.
Faulty link bearings.
Replace link assembly.
Link mounting loose.
Clean, lubricate, and retighten.
Malfunction
Grinding, rubbing, knocking noises
when pedal levers rotate under
load.
Probable Cause
Corrective Action
Excessive end play in rocker arms.
Adjust collars as necessary to take

out the end play. See How To
Replace Rocker Arms.
Pedal lever vibrates or squeaks during

operation.
Align pedal lever. See How To

Replace Pedal Lever.
Pedal tape not adhering properly.
See How To Replace Pedal Lever
Drive Belt slipping.
Loose or worn belt.
Check belt tension using a J10 belt

gauge. The belt deflection should be
1/4 (7mm) at 170 lb for a new belt
and 160 lb for an existing belt.
Upper Arms feel loose.
Bolts that connect the upper and

lower arms are loose.
Adjust and tighten to a torque of 3035 ft lb.
Front to back play in pedal lever.
Worn bearings.
Check for front to back movement in

bearings that connect pedal lever to
the rocker arm. Replace pedal lever
assembly.
Poly V-Pulley on intermediate shaft is

loose.
Replace intermediate shaft

assembly.
Crankarm loose.
Loosen setscrews and clamping

screw in Crankarm Assembly. Apply
blue Loctite 242 on screws. Tighten
setscrews first and then tighten the
clamping screw.
Worn link bearings.
Replace link.
Loose link mounting.
Clean, lube, and reassemble.
No Load.
Faulty cables, power console board,

or alternator.
Enter diagnostic state 3 and execute

the field duty cycle and increase the
load. If load does not increase,
replace alternator.
No LEDs on display.
Faulty display console.
Using a voltmeter, verify 8Vdc at the

10 position Molex connector pin 1 on
the display console PCB. If voltage
is present, replace display console.
If not, replace power control board.
Section I
Faulty power control board.
Using a voltmeter, verify 8Vdc at 11

position connector pin 4 on the
power control board. If present,
replace console cable. If not, replace
board.
Malfunction
Probable Cause
Corrective Action
Alternator belt slipping.
Belt is loose.
Retension from 65-70 lb.
No heart rate or erratic heart rate.
Pinched cable in Monocolumn cover.
Remove monocolumn covers and

inspect cables. Replace damaged
cable.
Defective chest strap or improperly

positioned.
Replace chest strap or reposition it.

Reset transmitter. Refer to
Diagnostics state 3 to execute the
heart rate test.
No heart rate reading.
Execute Diagnostic Mode to verify

performance of heart rate function.
Faulty cable connection.
Verify heart-rate cable is properly

connected. Using an ohmmeter,
verify continuity at the main console
cable.
Malfunctioning user arm/Lifepulse

(CT9500HR) Grip Assembly (include
worn or damaged heart rate lead).
Replace user arm/Lifepulse

(CT9500HR) Assembly.
Life Pulse user arm defective.
Verify user arm is functioning. Wipe

sensors dry. Using an ohmmeter,
verify continuity between Lifepulse
sensor and cable connection.
Replace if defective.
Loose or malfunctioning heart rate

lead connection at Display Console.
Secure connection. Replace

malfunctioning user arm/Lifepulse
(CT9500HR) Grip Assembly.
Heart-rate (DSP) Board (CT9500HR)

is faulty or not communicating.
Verify that the heart-rate (DSP)

board (CT9500HR) is communicating. If defective, replace.
Malfunctioning Display Console.
Test with known good Display

Console. Replace malfunctioning
Display Console.
Cross talk from telemetry and another

transmitter or possible interference
from other electronic devices.
Position Cross-Trainer at least 3 ft

(1 m) from unit with telemetry or from
other electronic devices.
Bad connection.
Check for corrosion on connectors.

Disconnect and reconnect telemetry
receiver.
Malfunction
No LEDs or random LEDs lit.
Probable Cause
Corrective Action
Cable connection faulty.
Remove display console and verify

cable is properly plugged into
console.
Main wire harness damaged.
Check for a damaged wire harness.

Replace wire harness.
No RPM. Unit shuts off one minute

into program.
Bad cable connection.
Verify cables connections at console

to power control PCB, and power
control PCB to alternator.
Disconnect and reconnect cables.
Using a voltmeter, verify cable
continuity on console to power
control PCB and power control PCB
to alternator.
Auto start failure
No RPM
Operator must be pedling unit for the

auto start feature to activate.
Battery
Battery voltage should be 5.8 6.3

Vdc. If not, replace the battery.
Bad cable connection.
Verify cables connections at

console, board, and reed switch are
correct and connected properly.
Magnet
Verify that magnet is on crank

pulley. If magnet is not present,
reinstall magnet.
Faulty reed switch or board.
Perform a continuity test. Inspect

reed switch for damage. If
necessary, replace the board.
Dead battery after C-Safe card is

installed.
Replace battery if under 5 VDC and

reset jumpers in C-Safe card. See
How To Set Jumpers.
Section I
NOTES:
Section II
SECTION II
DIAGNOSTIC MODES
CT8500, CT9100, and CT9500HR Display Consoles
The following three(3) Display Consoles are representative for each model crosstrainer. The following Diagnostic State
pages depict a CT9100 Display Console. Regardless of Display Console, the Message Center always provides current
Diagnostic Data.
Level
Heart Rate
Cal/Hour
Calories
Distance
Watts
H E AR T R A T E
179
170
120 1 1 7
162
153 145
136
1 2 8 119
111
102
85%
80%
114
111 108
105
102 9 9
65%
96
93 6 0 %
10 20 30 40 50 60 70 80 90 100
AGE
Quick Start:
1 2 3
4 5 6
7 8 9
0
Aerobics
Mode
Reverse
Mode
Press Start
Press Quick Workout
Time
Clear
Pause
Quick
Workout
Display
Lock
179
Start
Start
120
170
162 1 5 3
145
136
128 119
111
102
85%
80%
117
114
111 108
105 102
65%
99
96
9 3 60%
10 20 30 40 50 60 70 80 90 100
Quick Start:
A G E
Enter
Enter
RPM
H EA R T R A T E
120 1 1 7
136
128
Level
Heart Rate
Cal/Hour
Calories
Distance
Watts
119 111
102
Display
Display
Lock
111 108
105
102
99
93
179 170
Quick
Workout
AGE
1 2 0 117
162
153 145
136
Aerobics
Mode
Reverse
Mode
Clear
Pause
Quick
Workout
Start
Enter
Enter
Life Fitness USA:1-800-735-3867

Life Fitness Intl.: (+1) 847-288-3300
Life Fitness UK: (+44) (0)1353 666017
128
Heart Rate
Calories
Distance
119 111
102
111 108
105
102
99
Display
Lock
Pause
Pause
Quick
Workout
85%
93
AGE
60%
Quick Start:
Start
Press Start
Press Quick Workout
Enter
Enter
Enter
Enter
Life Fitness USA: 1-800-735-3867
Life Fitness Intl.:(+1) 847-288-3300
Life Fitness UK: (+44) (0)1353 666017
CT9100
Clear
Clear
65%
96
10 20 30 40 50 60 70 80 90100
Quick Start:
Press Start
Press Quick Workout
Level
80%
114
Start
60%
RPM
Pause
Pause
65%
96
10 20 30 40 50 60 70 80 90 100
Clear
Clear
Aerobics Reverse
Aerobics
Mode
Mode
Mode
85%
Time
80%
114
1 2 3
4 5 6
7 8 9
0
CT9500HR
HE A RT RA T E
Time
153 145
Cal/Hour
Watts

Life Fitness Intl.:(+1) 847-288-3300
Life Fitness UK: (+44) (0)1353 666017
CT9500HR (Display Lock Equipped)
162
Heart Rate
Distance
Press Start
Press Quick Workout

Life Fitness UK: (+44) (0)1353 666017
179 1 7 0
Level
Calories
RPM
CT8500
Section II
RPM
H E A R T R AT E
Time
ENTERING DIAGNOSTIC STATES 1-17
To enter the diagnostic mode, proceed as follows:
2.
3.
4.
5.
6.
Press down and hold the DOWN ARROW key. While doing this, press the CLEAR (CT9100) or CLEAR/PAUSE
(CT9500) key twice within 2.5 seconds. The console will go blank momentarily, but do not release the DOWN
ARROW key. As soon as the MESSAGE CENTER displays the word DIAGNOSTICS, then release the DOWN
ARROW key.
Press the ENTER key to scroll through diagnostic states 1-17.
Press the UP and DOWN ARROW keys to activate a selection within a diagnostic state.
Press the CLEAR key to scroll back to a previous diagnostic state
Press the CLEAR key as required to exit out of the diagnostic program.
For diagnostic states that have a subdirectory, press the DISPLAY LOCK key to enter.
Section II
1.
NOTE: RPM diagnostic mode requires pedaling.

NOTE: Factory defaults are displayed when the LED is illuminated on the ENTER key.
DIAGNOSTIC STATE 1 - LEDs and KEYPAD TEST
Time
RPM
Level
Calories
Heart Rate
Distance
Cal/Hour
Watts
248
HE AR T R ATE
Message
Center
179
170
162
153145
136
128
119
111
102
85%
120
117
114
111
108105
102
Display
Display
Lock
Clear
Clear
Aerobics
Mode
Reverse
Quick
Mode Workout
Pause
Pause
80%
99
96
65%
9 3 60%
10 20 30 40 50 60 7 0 80 90 100
AGE
CAUTION: CONSULT A PHYSICIAN BEFORE USING THIS EQUIPMENT.

STOP EXERCISING IF YOU FEEL PAIN, FAINT, DIZZY OR SHORT OF BREATH
ATTENTION : CONSULTEZ UN MDECIN AVANT DUTILISER CET APPAREIL.
ARRTEZVOUS SI VOUS AVEZ DES DOULEURS, SI VOUS VOUS SENTEZ
FAIBLE, TOURDI OU COURT DE SOUFFLE.
Start
Quick Start:
Press Start
Press Quick Workout
Enter
Enter

Profile
Window
Initially all LEDs are lit. When pressing the keys listed below, the appropriate character should display across the
MESSAGE CENTER.
CROSS-TRAINERS 8500 AND 9100

KEY MODE DEPRESSED
Display Lock
Clear
Pause
Aerobics Mode
Reverse Mode
Quick Workout
Up Arrow
Down Arrow
Start
Enter
CHARACTER DISPLAYED
L
P
A
R
Q
U
D
-
Press the CLEAR key to exit diagnostic mode.

Press the ENTER key to advance to Diagnostic State 2.
CROSS-TRAINER 9500
KEY MODE DEPRESSED
Clear Pause
Quick Workout
Aerobics Mode
Reverse Mode
Up Arrow
Down Arrow
Numeric Keys 0-9
Start
Enter
CHARACTER DISPLAYED
Q
A
R
U
D
Numeric Value
-
DIAGNOSTIC STATE 2 - INDIVIDUAL LED TEST
HEAR T RATE
179170
162
153 145
136
120117
114
111108
105
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
Display
Display
Lock
128
119111
102
85%
Clear
Clear
Pause
Pause
Section II
Time
Aerobics
Aerobics Reverse Quick
Mode
Mode Workout
Mode
80%
102
99 96
65%
Start
9 3 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

In this test, the system scrolls through each LED automatically to test its functionality.
Press the CLEAR key to return to Diagnostics State 1.
Press the ENTER key to advance to Diagnostics State 3.
DIAGNOSTIC STATE 3 - Code Version and RPM, Heart Rate, and LDC
Tests
Time
PX.XX
HEAR T RATE
Level
Calories
RPM
HR
179170
162
153145
136
128
119111
102
85%
120117
114
111108
105
102
Heart Rate
Distance
Cal/Hour
Watts
0
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

The items displayed for selection are Code Version, RPM, Heart Rate, and Load Duty Cycle (LDC).
Code Version will be displayed under the TIME segment and will be a four(4) digit number. Press the DISPLAY LOCK
key or the 8 key (CT9500) to access software part number xxxx-xxxxx-xxxx. To go back to the original diagnostic
screen press the DISPLAY LOCK key or the 8 key (CT9500).
To verify the RPM signal, pedal and observe RPM value.
To verify that the heart rate system is functioning properly, use a polar simulator or a chest strap. If the unit functions
correctly the Heart Rate LED will illuminate and a heart rate value will be displayed in the MESSAGE CENTER under
the LEVEL and CALORIES segment. Otherwise if heart rate is not detected then the HR characters will be displayed
and the HEART RATE LED will not be lit.
While pedaling, press the ARROW keys to verify the alternator LOAD DUTY CYCLE. Using the UP ARROW, increase
load resistance from 0 to 250. Zero (0) equals a no Load Duty Cycle (LDC) state. 250 equals 100% of LDC. The Load
Duty Cycle value will be located under the HEART RATE and DISTANCE segment.
NOTE: Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10%
(CT9100/8500 feature). Use 4 and 6 KEYS to increment and decrement LDC value by 10% (CT9500 feature).
DIAGNOSTIC STATE 3 - Code Version and RPM, Networking, and LDC

Tests
(DISPLAY LOCK EQUIPPED MODEL ONLY)
Level
Calories
RPM
HEART R ATE
179
170
120 117
162 153
145 136
128
119
111 102
85%
80%
114
111 108
105
102
99
65%
96
93 60%
10 20 30 40 50 60 70 80 90 100
AGE
Quick Start:
Heart Rate
Distance
Cal/Hour
Watts
1 2 3
4 5 6
7 8 9
0
Aerobics
Mode
Reverse
Mode
Press Start
Press Quick Workout
Clear
Pause
Section II
Time
Quick
Workout
Display
Lock
Start
Enter
Enter

Life Fitness UK: (+44) (0)1353 666017
The items displayed for selection are Code Version, RPM, Networking, and Load Duty Cycle (LDC).
Code Version will be displayed under the TIME segment and will be a four(4) digit number. Press the DISPLAY LOCK
key or the 8 key (CT9500) to access software part number xxxx-xxxxx-xxxx. To go back to the original diagnostic
screen press the DISPLAY LOCK key or the 8 key (CT9500).
To verify the RPM signal, pedal and observe RPM value.
While pedaling, press the ARROW keys to verify the alternator LOAD DUTY CYCLE. Using the UP ARROW, increase
load resistance from 0 to 250. Zero (0) equals a no Load Duty Cycle (LDC) state. 250 equals 100% of LDC. The Load
Duty Cycle value will be located under the HEART RATE and DISTANCE segment.
The status of the LIFELINK board and LIFECENTER connection will be displayed in the CALORIES window. The
following message will be displayed:
NONE = No LIFELINK board detected
NULL = Board detected but not communicating
ON = Online status with Life Center
OFF = Offline status with Life Center
NOTE: Use the PAUSE and QUICK WORKOUT keys to increment and decrement the LDC value by 10%
(CT9100/8500 feature).
7
DIAGNOSTIC STATE 4 - FIELD/ALTERNATOR-REGULATOR TEST
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
FIELD/ALTREG TST
HEART RATE
179170
162153
145136
128
119111
102
85%
120
117114
111108
105102
Display
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

Prior to enter the test modes, set the field load duty in diagnostics state 3 to 50. Press the Display Lock key, or the
number 2 key for CT9500 only, once to access Field Test. Use the UP/DOWN ARROW toggle the field voltage ON
and OFF. This will verify the operation of the alternator and cable connections. The resistance should increase as the
field test is turned on.
Press the Display Lock key, or the number 2 key for CT9500 only, again to access the Alternator/Regulator Test. Use
the UP/DOWN ARROW key to toggle voltage ON/OFF. This will verify that the power control board is regulating the
voltage properly and the load resistance should slightly decrease as the alternator/regulator is turned on.
DIAGNOSTIC STATE 5 - PROGRAM VERSION AND NETWORKING TEST
PX.XX
PX.XX
HEART RATE
Cal/Hour
Watts
NONE
128
119111
102
85%
120
117114
111108
105102
Heart Rate
Distance
Display
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
Quick Start:
AGE

Press Start
Press Quick Workout
Enter
Enter

The PROGRAM VERSION NUMBER for 68HC05 micro controller code version will be displayed in the elapsed time
window (e.g. P_. _0).
The PROGRAM VERSION NUMBER for HEART RATE DSP Board will be displayed in the speed window
(eg. P_. _0).
The status of the LIFELINK board and LIFECENTER connection will be displayed in the CALORIES window. The
following message will be displayed:
NONE = No LIFELINK board detected
NULL = Board detected but not communicating
ON = Online status with Life Center
OFF = Offline status with Life Center
10
Section II
RPM
179170
162153
145136
Level
Calories
Time
DIAGNOSTIC STATE 5 LIFEPULSE TEST

Time
Level
Calories
RPM
H E A R T R AT E
179 170
120 117
162 153
145
136
128 119
111 102
85%
80%
114
111 108
105
102 99
65%
96
93 60%
10 20 30 40 50 60 70 80 90100
AGE
Quick Start:
Press Start
Press Quick Workout
Heart Rate
Distance
Cal/Hour
Watts
1 2 3
4 5 6
7 8 9
0
Aerobics
Mode
Reverse
Mode
Clear
Pause
Quick
Workout
Display
Lock
Start
Enter
Enter

Life Fitness UK: (+44) (0)1353 666017
Upon initial entry to this test, a message concerning the configuration of the lifepulse system being On or Off. This
test will allow the user to test the lifepulse heart rate system.
Following this message, the lifepulse system can be manually tested. A heart will be in the profile window.
The system will show when the user has placed their hands on the lifepulse sensors. When the left sensor detects
hands on condition, a L will be placed in the profile window with the heart. When the right sensor detects hands on
condition, a R will be placed in the profile window with the heart.
A timer will start counting from the time when a both left and right hands on condition occurs to when the lifepulse
system can reliable give the user their heart rate. This timer will stop when the heart rate is given.
The gain value of the heart rate signal is shown. The confidence level of the heart rate value is displayed. The value
ranges from 0 to 9. A value of 9 is considered to be high confidence. A value of 0 is considered to be low confidence.
11
DIAGNOSTIC STATE 6 - MAXIMUM WORKOUT DURATION
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
HE AR T RAT E
179170
162
153145
136
120
117114
111108
105
128119
111
102
85%
Display
Display
Lock
Clear
Clear
Aerobics
Aerobics
Mode
Mode
Reverse Quick
Mode
Workout
Pause
Pause
80%
102
99 96
65%
Start
93 60%
10 20 30 40 50 60 70 80 90 100
Quick Start:
AGE

Press Start
Press Quick Workout
Enter
Enter

Maximum program duration can be adjusted from a range between 60-99 minutes. Press the DOWN ARROW to
decrease values in decrements of 1 minute. Press the UP ARROW key to increase values in increments of 1 minute.
The LED on the ENTER key will illuminate when the value is set to the default of 60 minutes. This value is stored in
EEPROM and is stored when the cross-trainer is not in use.

12
Section II
MAX DURATION 60
DIAGNOSTIC STATE 7 - TELEMETRY ON/OFF
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
TELEMETRY ON
HEART R ATE
Display
Display
Lock
179170
162
153145
136128
119
111
10285%
120
117114
111108
105
102 99
Clear
Clear
Pause
Pause
Aerobics
Aerobics Reverse
Mode
Mode
Mode
Quick
Workout
80%
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
Quick Start:
AGE

Press Start
Press Quick Workout
Enter
Enter

The default is TELEMETRY ON (CT91/95) TELEMETRY OFF (CT85). Press the DOWN ARROW to turn OFF
telemetry and the UP ARROW to turn it back ON. A heart shape illuminates in the program profile window.
The ENTER key LED illuminates to indicate when TELEMETRY ON. This value is stored in EEROM while the crosstrainer is not in use.
Press the CLEAR key to return to Diagnostic State 6.
13
DIAGNOSTIC STATE 8 - ENGLISH OR METRIC UNITS
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
HEART RATE
179170
162153
145136
128
119111
102
85%
120
117114
111108
105102
Display
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
Quick Start:
AGE

Press Start
Press Quick Workout
Enter
Enter

ENGLISH or METRIC units can be selected. Press the DOWN ARROW to select METRIC units. Press the UP
ARROW to select ENGLISH.
The ENTER key LED illuminates when defaulted to ENGLISH UNITS. This value is stored in EEROM and is kept when
the cross-trainer is not in use.
Press the CLEAR key to return to Diagnostic State 7

Press the ENTER key to advance to Diagnostic State 9
14
Section II
ENGLISH UNITS
DIAGNOSTIC STATE 9 - POWER SUPPLY TYPE
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
BATTERY
HEART RATE
179170
162153
145136
128
119111
102
85%
120
117114
111108
105102
Display
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
Quick Start:
AGE

Press Start
Press Quick Workout
Enter
Enter

There are two types of power supply sources (BATTERY and EXTERNAL).
Make sure that the displayed value is BATTERY. If need be, change the value to BATTERY by pressing the UP
ARROW key.
NOTE: If external power is turned ON, the 6 volt rechargeable battery will be drained.
15
DIAGNOSTIC STATE 10 - SHUTDOWN TIME
Time
RPM
Level
Calories
Heart Rate
Distance
Cal/Hour
Watts
HEART RATE
179170
162153
145136
128
119111
102
85%
120
117114
111108
105102
Display
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

If BATTERY is selected, then SHUTDOWN TIME must be set. The SHUTDOWN TIME (BATTERY only) is set in
seconds from 1 to 60. The time specified will shut off the Cross-Trainer when no RPMs are detected.
Pressing the CLEAR/PAUSE key will return to Diagnostics State 9.
Pressing the ENTER key will advance to Diagnostics State 11.
16
Section II
SHUTDOWN TIME 60
DIAGNOSTIC STATE 11 - PROGRAM TIME
Time
RPM
Level
Calories
Heart Rate
Distance
Cal/Hour
Watts
PROGRAM TIME 60
HEART R ATE
Display
Display
Lock
179170
162
153145
136128
119
111
10285%
120
117114
111108
105
102 99
Clear
Clear
Pause
Pause
Aerobics
Aerobics Reverse
Mode
Mode
Mode
Quick
Workout
80%
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

The PROGRAM TIME, is the maximum time allowed for inputting weight, age, etc. If no entry to program is made after
the set program time from 60-99 seconds, the unit automatically shuts off.
NOTE: If no keys are pressed, the unit will shut down after 15 seconds, not 60-99.
Pressing the CLEAR/PAUSE key will return to Diagnostics State 10.
Pressing the ENTER key will advance to Diagnostics State 12.
17
DIAGNOSTIC STATE 12 STATISTICS
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
HEAR T RATE
179170
162
153145
136
128
119111
102
85%
120117
114
111108
105
102
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

Press the UP ARROW to scroll forward through the programs for number of times each program has been selected.
Press the DOWN ARROW to scroll backwards through the programs to display total hours.
STATISTICS
HOURS
HILL
RANDOM
MANUAL
FAT
CARDIO
X-REV
X-AERO
QUICK
HR-WIPE
18
Number of hours
Number of times
Number of times
Number of times
Number of times
Number of times
Number of times
Number of times
Number of times
Number of times wiping of hand sensor message
Section II
STATISTICS
DIAGNOSTIC STATE 13 - METS ENABLE/DISABLE
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
METS OFF
HEAR T RATE
179170
162
153145
136
128
119111
102
85%
120117
114
111108
105
102
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

Press the DOWN ARROW to disable the METS mode. Press the UP ARROW to enable the METS mode.
METS is the expression of the rate of work (power output). One MET is approximately equal to a persons metabolism
when seated and relaxed.
When the value is set to METS OFF default the ENTER key LED will illuminate.
This value is stored in EEPROM and is stored when the cross-trainer is not in use.
19
DIAGNOSTIC STATE 14 - KEYPAD SELECTION
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
HEAR T RATE
179170
162
153145
136
128
119111
102
85%
120117
114
111108
105
102
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

To select the appropriate keypad press the UP/DOWN ARROW keys for the designated model. Make sure that the
system displays CT9500 K-PAD ON, CT91/55 K-PAD ON or CT8500 K-PAD ON depending machine model.
20
Section II
CT91/55 K-PAD ON
DIAGNOSTIC STATE 15 - TOGGLE ENABLE/DISABLE
Time
Level
Calories
RPM
Heart Rate
Distance
Cal/Hour
Watts
TOGGLED DISABLED
HEART RATE
179170
162153
145136
128
119111
102
85%
120
117114
111108
105102
Display
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

To select the appropriate default press the UP/DOWN ARROW keys until the message TOGGLE DISABLED,
WATTS TOGGLE ON, CAL/HR TOGGLE ON, or CAL/HR WTTS TGGL is displayed. These are different options
the customer can select to have the display console toggle from one item to another.
21
DIAGNOSTIC STATE 16 PHOTOSHOOT
RPM
28:45
52
HEAR T RATE
Level
Calories
372
179170
162
153145
136
128
119111
102
85%
120117
114
111108
105
102
Heart Rate
Distance
Cal/Hour
Watts
135
Display
Lock
Clear
Clear
Pause
Pause
Aerobics
Aerobics
Mode
Mode
Reverse
Mode
Quick
Workout
80%
99
65%
96
Start
93 60%
10 20 30 40 50 60 70 80 90 100
AGE

Quick Start:
Press Start
Press Quick Workout
Enter
Enter

Display values that have no significance and are used strictly for photographic sessions to assimilate values in the
display console.
Press the CLEAR key to return to Diagnostic State 15 or continue to press the CLEAR key to exit diagnostics.
22
Section II
Time
DIAGNOSTIC STATE 16 LANGUAGE CONFIGURATION

Time
RPM
Level
Calories
HEA RT RATE
179
170
120 117
162 153
145 136
128
119 111
102
85%
80%
114
111 108
105
102 99
65%
96
93 60%
10 20 30 40 50 60 70 80 90 100
AGE
Quick Start:
Press Start
Press Quick Workout
Heart Rate
Distance
Cal/Hour
Watts
1 2 3
4 5 6
7 8 9
0
Aerobics
Mode
Reverse
Mode
Clear
Pause
Quick
Workout
Display
Lock
Start
Enter
Enter

Life Fitness UK: (+44) (0)1353 666017
This test allows the user to select a language for the unit. Upon initial entry to this test, a message concerning the
current configuration of the language is displayed. Following this message, the user can change the language by
pressing the arrow key to scroll through the available list of language in the product. After the language has been
selected, pressing Clear or Enter keys will cause the product to save the language selected.
23
DIAGNOSTIC STATE 17 PHOTOSHOOT

RPM
28:45 52
Level
Calories
372
H EA RT RA T E
179
170
120 117
162 153
145 136
128
119 111
102
85%
80%
114 111
108
105 102
99
65%
96
93 60%
10 20 30 40 50 60 70 80 90 100
AGE
Quick Start:
Press Start
Press Quick Workout
Heart Rate
Distance
Cal/Hour
Watts
135
1 2 3
4 5 6
7 8 9
0
Aerobics
Mode
Reverse
Mode
Clear
Pause
Quick
Workout
Display
Lock
Start
Enter
Enter

Life Fitness UK: (+44) (0)1353 666017
Display values that have no significance and are used strictly for photographic sessions to assimilate values in the
display console.
Press the CLEAR key to return to Diagnostic State 16 or continue to press the CLEAR key to exit diagnostics.
24
Section II
Time
NOTES:
25
SECTION III
Section III
How To... SERVICE AND REPAIR GUIDE
How To... Replace the Display Console

Tools required: Phillips screwdriver
1.
2.
Remove the MOUNTING SCREWS(4) from under

the CONSOLE.
3-Pin
Connector
Lift the console up enough to disconnect the 10-Pin

and 3 or 4-Pin connectors.
Console
Spacer
Accessory Tray
3.
Remove the console and spacer from the console

post or if equipped, the accessory tray which is
standard on CT95/91 and optional on CT85.
4.
Install new console in reverse order.
(Optional on CT85 only)
Display
Console
Screws(4)
10-Pin
Connector
4-Pin
Connector
(9500 only)
Console
Support
Assembly
How To... Replace the Accessory Tray (Optional on CT8500)

Tools required: Phillips screwdriver, Allen wrench set, and 3/8 Standard wrench set
2.
3.
4.
5.
Remove the MOUNTING SCREWS(4) from

under the CONSOLE.
Accessory
Tray
3-Pin
Connector
Lift the console up enough to disconnect

the 10-Pin, 3-Pin or 4-Pin connectors.
Remove the console and spacer from the
accessory tray.
Remove the ACCESSORY TRAY
BOLTS(4) and NUTS(4), and lift off the
ACCESSORY TRAY from the console
post.
Install new accessory tray in reverse order.
Console
10-Pin
Connector
Spacer
Wire
Harness
Accessory
Tray Screws(4)
Accessory
Tray Nuts(4)
Display
Console
Screws(4)
4-Pin
Connector
(9500 only)
Console
Support
Assembly
Section III
1.
How To... Replace the Display Console Support Assembly

Tools required: Phillips screwdriver and Allen wrench set
Rocker Cover and Screws(3)
Polar
Receiver
Monocolumn
Cover
Back
Rocker
Cover
Foam Insulator
Monocolumn
Cover
Monocolumn
Cover
Foam Insulator
Model 8500/9100 Shown
Polar
Receiver
Monocolumn
Cover
Monocolumn
Cover Screws(2)
Front Rocker
Cover
Model 9500HR Shown
Monocolumn
Cover Screws(4)
Front Rocker
Cover and Screws(3)
1.
Remove the console and accessory tray. See How To.
2.
Remove the MONOCOLUMN COVER (ALL

MODELS) and ROCKER ARM COVERS (9500).
3.
4.
5.
6.
3-Pin
Connector
Accessory
Tray
Console
Remove the POLAR RECEIVER.

Remove the two(2) HEX HEAD CAPSCREWS and
FLAT WASHERS securing the CONSOLE
SUPPORT ASSEMBLY.
10-Pin
Connector
Spacer
Accessory
Tray Screws(4)
Accessory
Tray Nuts(4)
Lift the CONSOLE POST out of the

MONOCOLUMN while guiding the wire harness
out.
Install new console support in reverse order.
4-Pin
Connector
(Model 9500)
Display
Console
Screws(4)
Console
Support
Assembly
Hex
Bolts(2)
Wire
Harness
Flat
Washers(2)
Monocolumn
How To... Replace The Rear Covers

Tools required: Phillips magnetic screwdriver #2, Allen wrench set, 3/8 Socket set, and Standard wrench set
1.
Remove the OUTER LINK COVER

by removing six(6) mounting
screws from each OUTER LINK
COVER.
Pedal Lever Nuts(2)

Torque
30-35 FT. LBS.
Rocker Arms
Rear Cover RH
Bolt
Remove the ANTI-LIFT BRACKET

by removing two(2) mounting bolts
from each bracket.
3.
Remove the clevis cover from each

pedal lever.
4.
Remove the PEDAL LEVER by

removing the mounting bolt and nut
at each ROCKER ARM joint and
the hex bolt fom each ARM
EXTENSION.
Rear Cover LH
5.
Remove the PLUG from the LEFT

and RIGHT COVERS.
6.
Remove the REAR COVER by removing

three(3) screws from the LEFT REAR
COVER then seven(7) screws from the
RIGHT REAR COVER.
7.
Install rear covers in reverse order. Make

sure that each pedal lever roller guide is
centered over the roller. If not, lossen the
pedal lever assembly mounting bolt and
recenter the pedal lever so that it is
centered on the roller, then retighten the
Plug
Bolt
Clevis
Covers
Pedal Lever RH
Arm Extension
Hex Bolt
Left
Rear
Cover
Anti-Lift
Bracket
Anti-Lift Bolts(2)
Torque
30-35 FT. LBS.
Cover Screws(6)
Torque
6-10 IN. LBS.
Outer Link
Cover RH
Section III
2.
Right
Rear
Cover
Plug
Pedal Lever
Assembly
Pedal Lever
Roller Guide
mounting bolt.
Crankarm
Shaft
YES
NO
Correct Position
of the Roller
Incorrect Position
of the Roller
Roller
END VIEW OF
PEDAL LEVER
How To... Replace The Crankarm Roller Assembly and Cover

Tools required: Snap ring pliers and Allen wrench set, and Phillips screwdriver
1.
Remove the REAR COVERS. See How To Remove Rear Covers.
2.
Remove the ALLEN-HEAD CAPSCREW

from the end ot the ARM EXTENSION.
3.
Crankarm
Cover
Remove the SNAP RING, TAB WASHER

and ROLLER BEARING ASSEMBLY on
Old configuration assembly. For New
configuration assembly, remove the
setscrew and collar, then remove the
roller bearing assembly.
4.
Remove the two(2) countersunk screws

securing the crankarm cover to the
crankarm, and remove the CRANKARM
COVER.
5.
Install the CRANKARM COVER and

ROLLER BEARING in the reverse order.
For new style roller bearing assemblies,
make sure that a maximum of .005"
clearance is maintained between the
ROLLER BEARING and the COLLAR.
Crank Cover
Roller Bearing
Assembly
Arm
Extension
Snap
Ring
Tab
Washer
Allen-head
Cap screw
Torque 30-35 ft lbs
Screws(2)
Torque 65-75 in lbs
Old Style
Roller Bearing Assembly
Crankarm
Cover
Roller Assembly
MUST Turn Freely
After Assembly
.005 MAX
Clearance
Collar
Arm
Extension
Torque
30-35 ft lbs
Arm Extension
Torque 28-33 in lbs
(2 places)
Collar
NEW STYLE
How To... Replace The Crankarm Assembly

Tools required: Snap ring pliers and Allen wrench set, and Phillips screwdriver
1.
Remove the REAR COVERS. See How To Remove

Rear Covers.
2.
Remove the ALLEN-HEAD CAPSCREW from the end

ot the ARM EXTENSION.
3.
Remove the SNAP RING, TAB WASHER and

ROLLER BEARING ASSEMBLY on Old configuration
assembly. For New configuration assembly, remove
the SETSCREW and COLLAR, then remove the roller
bearing assembly.
4.
Crankarm
Cover
Roller Bearing
Assembly
Arm
Extension
Snap
Ring
Tab
Washer
Remove the two(2) countersunk screws securing the

crankarm cover to the crankarm, and remove the
CRANKARM COVER.
Allen-head
Cap screw
Torque 30-35 ft lbs
Screws(2)
Torque 65-75 in lbs
Old Style
Remove the NUT and BOLT from the CRANKARM.
6.
Remove the SETSCREW and KEY from

the CRANKARM.
7.
Crank Cover
Crankarm
Cover
Roller Bearing Assembly
Roller Assembly
MUST Turn Freely
After Assembly
Remove the CRANKARM off the shaft.
.005 MAX
Clearance
Collar
8.
Install the CRANKARM COVER and

ROLLER BEARING in the reverse order.
For new style roller bearing assemblies,
make sure that a maximum of .005"
clearance is maintained between the
ROLLER BEARING and the COLLAR.
Section III
5.
Arm
Extension
Torque
30-35 ft lbs
Arm Extension
Torque 28-33 in lbs
(2 places)
Collar
NEW STYLE
Crankarm Cover
Crankarm Nut
Crankarm Assembly
Arm Extension
Crankarm Bolt
Crankarm
Setscrew
Key
BACKSIDE VIEW
How To... Replace The Drive Belt and Alternator Belt

Tools required: 3/8 Socket set and Standard wrench set, and Phillips screwdriver
Alternator Belt
New: 75-85 lbs
Used: 60 lbs
Main Drive Belt
New: 170 lbs
Used: 160 lbs
Pivot Bolt
Torque
50-60 ft lbs
Crankshaft
Pulley Assembly
Mounting Bolt
Torque
18-20 ft lbs
Intermediate
Pulley
Alternator
Support Bracket
Torque
30-35 ft lbs
Pillow Bock
Bearing Nuts
Torque
30-35 ft lbs
1.
Remove the both REAR COVERS. See How ToRemove Rear Covers.
2.
Loosen the ALTERNATOR PIVOT BOLT and release tension on the alternator belt, then remove the
ALTERNATOR BELT off the INTERMEDIATE PULLEY.
3.
Loosen the five(5) mounting bolts on the ALTERNATOR BRACKET and move the bracket upward and remove the
DRIVE BELT off the crankshaft pulley assembly.
4.
Remove the CRANKSHAFT PULLEY ASSEMBLY by removing four(4) mounting bolts at the PILLOW BLOCK
BEARINGS.
5.
Remove and discard the DRIVE BELT.
6.
Install new drive belt and alternator belt in reverse order.
How To...Remove Power Control Board Assembly

Tools Required: Slotted head screwdriver and Phillips screwdriver
1.
Remove the right REAR COVER. See How ToRemove

Rear Covers.
2.
Disconnect the 12 and 11-Pin Connectors on the PCB.
3.
Remove the PCB from its mounting bracket.
4.
Install new PCB in reverse order.
PCB
Mounting
Bracket
PCB
Section III
Torque
33-37 in lbs
Power Control
Board Bracket
Power
Control
Board
Torque
8-10 IN LBS
Spacers(4)
How To...Replace Alternator

Tools Required: 3/8 Socket set and Standard wrench set, and Phillips screwdriver
1.
Remove the REAR COVERS. See How

ToRemove Rear Covers.
2.
Disconnect the ALTERNATOR WIRING

HARNESS from the alternator.
3.
Remove the ALTERNATOR PIVOT BOLT

and MOUNTING BOLT, then lift out the
alternator.
4.
Install new alternator in reverse order.
Alternator
Pivot Bolt
Alternator
Mounting Bolt
Torque
18-20 ft lbs
Alternator
Belt
Nut
Torque
50-60 ft lbs
Alternator
Pivot
Bolt
Alternator Belt
New: 85 ft lbs
Used: 60 ft lbs
Intermediate
Pulley
Mounting Bolt
Torque
18-20 ft lbs
10
Main Drive Belt

New: 170 ft lbs
Used: 160 ft lbs
How To...Replace Alternator Belt

Tools Required: 3/8 Socket set and Standard wrench set, and Phillips screwdriver
2.
Remove the REAR COVERS. See

How ToRemove Rear Covers.
Loosen the ALTERNATOR PIVOT
BOLT and its MOUNTING BOLT.
3.
Rotate the alternator down to

release belt tension, then remove
the ALTERNATOR BELT.
4.
Install new alternator belt in

reverse order.
Rotate
Down
Alternator
Mounting
Bolt
Alternator
Pivot Bolt
Alternator Belt
New: 85 ft lbs
Used: 60 ft lbs
Section III
1.
11
How To... Replace Pedal Lever Assembly

Tools required: Phillip screwdriver, Allen wrench set, 3/8 Socket set, and Standard wrench set
1.
Remove six(6) screws from the OUTER LINK

COVER and remove cover.
2.
Remove the TIE ROD.
3.
Remove the CLEVIS COVER from each pedal

lever.
Pedal Lever Nuts(2)

Torque 30-35 FT. LBS.
Clevis
Covers
Rocker Arms
4.
Remove the ANTI-LIFT BRACKET and lower

the PEDAL LEVER ASSEMBLY.
5.
Remove the nut and bolt securing the pedal

lever to the ROCKER ARM, and remove the
pedal lever.
6.
Remove the inner link cover screws(4) and

remove the inner link cover.
7.
Install new pedal lever in reverse order except

as follow:
Bolts(2)
Rear Cover RH
Pedal Lever RH
Anti-Lift
Bracket
A) When tightening the clevis to the pedal

lever bolt, the pedal lever track must be
resting on the roller on the crankarm. See illustrastion below.
B) The identificaion mark on the tie rod must be
forward.
C) An identification mark on the tie rod must face
towards the front of the machine. Using a small
amount of Moly grease between the inner race
of the bearing and sleeve, attach the tie rod at
the rear of the machine first, then at the front.
Cover Screws(6)
Torque
6-10 IN. LBS.
Bolts(2)
Anti-Lift Bolts(2)
Torque
30-35 FT. LBS.
Outer Link
Cover
Spherical
Washer
Spherical
End
Sleeve
3-Turn
Wave
Spring
Linkage Nuts(2)
Torque
18-20 FT. LBS.
Thrust
Washer
Tie Rod
(Front end)
D) Use a small amount of grease between the

spherical washer and the spherical end sleeve.
Flat Washer
Front End View
Tie Rod
(Back end)
Shoulder
Sleeve
3-Turn
Wave
Spring
Pedal Lever
Assembly
Linkage Nuts(2)
Torque
18-20 FT. LBS.
Thrust
Washer
Flat Washer
Back End View
Pedal Lever
Roller Guide
Crankarm
Shaft
YES
NO
Correct Position
of the Roller
Incorrect Position
of the Roller
END VIEW OF
PEDAL LEVER
12
Roller
How To... Replace Rocker Arms

Tools required: 3/8 Socket set and Standard wrench set
1.
Remove the UPPER ARMS. See How

ToReplace User Arms.
End Cap
Torque
30-35 FT. LBS.
2.
Remove the MONOCOLUMN COVERS and

CLEVIS COVERS.
3.
Remove the clevis cover from each pedal lever.
4.
Remove the nut and bolt securing the PEDAL

LEVER to the ROCKER ARM, and lower the
pedal lever.
5.
Remove the END CAP from the rocker arm.
6.
Remove bolt and washer and slide-off the rocker

arm.
7.
Install new rocker arm in reverse order.
8.
Units with split collar design, make sure to position to within .005" gap of rocker arm. Units with one-piece collars,
make sure collar is positioned against shaft shoulder.
Bolts(2)
Rocker
Arm
Torque
30-35 ft lbs
Flat Washer
Shaft
Shoulder
Rocker
Arm
Rocker
Arm
Torque
30-35 ft lbs
One-Piece
Collar
Shaft
Flat Washer
Rocker
Arm
Flat Washer
Torque
30-35 ft lbs
Rocker Arm
Clevis
Covers
Split Collar
Flat Washer
Torque
30-35 ft lbs
Rocker Arm
13
Section III
Pedal Lever
How To... Replace Tie Rod

Tools required: Phillips magnetic screwdriver #2 and 3/8 Socket set
1.
Remove the OUTER LINK COVER by

removing the six(6) mounting screws.
2.
Remove the TIE ROD NUT from the

ARM EXTENSION and PEDAL ARM.
3.
Discard the tie rod and hardware.
4.
Install new TIE ROD in reverse order.
Clevis
Covers
NOTE: An identification mark on the tie rod

must face towards the front of the machine.
Using a small amount of Moly grease
between the inner race of the bearing and
sleeve, attach the tie rod at the rear of the
machine first, then at the front.
Cover Screws(6)
Torque
6-10 IN. LBS.
Bolts(2)
Outer Link
Cover
Spherical
Washer
Spherical
End
Sleeve
Linkage Nuts(2)
Torque
18-20 FT. LBS.
3-Turn
Wave
Spring
Thrust
Washer
Tie Rod
(Front end)
Flat Washer
Front End View
Tie Rod
(Back end)
Shoulder
Sleeve
3-Turn
Wave
Spring
Linkage Nuts(2)
Torque
18-20 FT. LBS.
Thrust
Washer
Flat Washer
Back End View
14
How To... Replace Crankshaft Pulley Assembly

Tools required: Allen wrench set, 3/8 Socket set, and Standard wrench set
Remove the REAR COVERS.
See How ToRemove Rear
Covers.
2.
See How ToRemove Alternator

Belt.
3.
Loosen six(6) mounting bolts on

the ALTERNATOR SUPPORT
BRACKET. Push this bracket up
to remove tension on the DRIVE
BELT, and remove the drive belt.
4.
5.
6.
Crankshaft
Plate Washer
Crankshaft
Pulley
Crankshaft
w/Plate
Pillow
Block
Bearing
Snap Ring
Pillow
Block
Bearing
Snap Ring
Bolts(4)
Torque
10-12 FT LBS
Remove four(4) bolts from the

CRANKSHAFT PULLEY
ASSEMBLY by removing four(4)
mounting bolts at the PILLOW
BLOCK BEARINGS.
Main Drive Belt

New: 170 ft lbs
Used: 160 ft lbs
Replace components on the

crankshaft pulley assembly as
necessary.
Section III
1.
Crankshaft
Pulley
Install new crankshaft pulley in

reverse order.
Pillow Block
Bearing
Pillow Block
Bearing Bolts
Pillow Block
Bearing Nuts
and Washers
Torque 30-35 ft lbs
15
How To... Replace The Intermediate Pulley

Tools required: 3/8 Socket set and Standard wrench set
1.

2.
Loosen the ALTERNATOR PIVOT BOLT and

rotate the alternator down to relieve belt
tension.
3.
Loosen the belt tension on the

INTERMEDIATE PULLEY by loosening the
five(5) bolts on the ALTERNATOR MOUNTING
BRACKET.
4.
Remove the INTERMEDIATE SHAFT BOLTand

the INTERMEDIATE PULLEY.
5.
Alternator
Pivot Bolt
Rotate
Down
Alternator
Bracket Bolt
Drive Belt
Alternator
Belt
Alternator
Mounting
Bracket
Install new INTERMEDIATE PULLEY in

reverse order.
Alternator
Pivot Bolt
Torque 50-60 ft lbs
Intermediate
Shaft Bolt
Alternator Belt
New: 85 ft lbs
Used: 60 ft lbs
Main Drive Belt

New: 170 ft lbs
Used: 160 ft lbs
Intermediate
Pulley
Alternator Bracket
Torque 30-35 ft lbs
16
How To... Replace Load Resistors

Tools required: Slotted screwdriver
Remove the right REAR COVER.
See How ToRemove Rear
Covers.
2.
Disconnect wires at the LOAD

RESISTORS.
3.
Remove the LOAD RESISTORS

by removing two(2) hex-head
screws securing the load resistor
to the frame.
4.
Install new load resistors in

reverse order.
Load
Resistors
Load Resistor Bracket

and Screws
Torque 33-37 in lbs
Load
Resistors
Section III
1.
17
How To... Replace The User Arms

Tools required: Allen wrench set and Phillips screwdriver
1.
MODELS 8500 and 9100: Raise the BOOT COVERS on the UPPER
ARMS.
MODEL 9500: Remove four(4) mounting bolts from the USER ARM
REAR COVERS and remove these covers.
2.
Remove three(3) MOUNTING BOLTS from each UPPER ARM and lift
off the user arm. Units with Heart Rate, disconnect electrical
connector.
3.
Install new user arms in reverse order.
Boot
Cover
Model 8500/9100
User Arm
Cover Screws
Lockwashers
User Arm
Hex Head
Cap Screws
User Arm
Rear Covers
User Arm
Front Covers
2-pin Connector
Rocker Arm
Model 9500
18
Model 9500HR
How To... Replace The Polar Receiver

1.
MODELS 8500 / 9100: Remove four(4)

mounting bolts from the two halves of the
MONOCOLUMN COVER and separate.
2.
MODEL 9500: Remove four(4) mounting

bolts from each USER ARM REAR
COVER(2). Then remove four(4) mounting
bolts from the MONOCOLUMN COVERS
and separate the two halves.
3.
Locate the POLAR RECEIVER in the

monocolumn and disconnect it from its
jack.
Monocolumn
Front Cover
Polar Receiver
Polar Receiver Foam
Monocolumn
Back Cover
4.
Install a new POLAR RECEIVER in
reverse order.
Models 8500 / 9100
Monocolumn
Screws
Section III
User Arm
Cover Screws
User Arm
Front Covers
Polar Receiver
Monocolumn
Front Cover
Polar Receiver Foam

User Arm
Front Covers
Monocolumn
Rear Cover
Monocolumn
Screws
Model 9500
19
How To... Replace Monocolumn Cover

1.
MODELS 8500 / 9100: Remove four(4)

mounting bolts from the two halves of the
MONOCOLUMN COVER and separate.
2.
MODEL 9500: Remove four(4) mounting bolts

from each USER ARM REAR COVER(2).
Then remove four(4) mounting bolts from the
MONOCOLUMN COVERS and separate the
two halves.
3.
Install new monocolumn covers in reverse

order.
Monocolumn
Front Cover
Monocolumn
Back Cover
Monocolumn
Screws
Models 8500 / 9100
User Arm
Cover Screws
User Arm
Front Covers
Polar Receiver
Monocolumn
Front Cover
Polar Receiver Foam
Monocolumn
Rear Cover
Monocolumn
Screws
Model 9500
20
User Arm
Front Covers
How To... Replace The Frame Cover

Tools required: Phillips screwdriver, Standard screwdriver, Allen wrench set, 3/8 Socket set, and Wrenches
2.
Remove the FRONT COVER.
3.
Remove the FRAME COVER which is adhered

to the frame with double-back tape.
4.
Install four(4) pieces of tape to the underside of

the cover, then install the FRAME COVER.
Front
Cover
Section III
1.
Frame
Cover
Double-back
Adhesive Tape
(Four pieces)
21
How To... Replace The Front Cover

Tools required: Phillips magnetic screwdriver #2
1.
Remove the FRONT COVER screws(6) and

separate the front cover halves.
2.
Install new front cover in reverse order.
Front
Cover
Screws
Front
Cover
Screws
Left
Front
Cover
Front
Cover
Screws
22
Right
Front
Cover
Frame
How To... Replace The Battery

Tools required: Phillips magnetic screwdriver #2
Remove the FRONT COVER screws(6) and separate
the front cover halves.
2.
Disconnect the BATTERY CABLES.
3.
Remove the battery mounting screws(2) and lift out the

BATTERY.
4.
Install new battery in reverse order.
Battery
Battery
Cables
Front
Covers
Section III
1.
23
How To... Replace The Rear Wheels and Axle

Tools required: Slotted screwdriver and Pliers
1.
Remove the AXLE CAP from the WHEEL AXLE.
2.
Remove the WHEELS and AXLE.
3.
Install new wheels, axle, and axle cap in the reverse direction.
Rear
Wheels
Axle
Cap
Wheel
Axle
Axle Cap
Wheel
24
How To... Replace The Endcaps

Tools required: Slotted screwdriver
Remove the endcaps from the LOWER ARMS.
2.
Remove the endcaps from the FRAME.
3.
Install new endcaps in reverse order.
Endcap
Section III
1.
Endcaps
25
How To... Replace Pedal

Tools required: Clean cloth, water, and isopropyl alcohol
1.
Remove the pedals from the pedal arm assemblies.
2.
Remove old tape.
3.
Using a clean cloth, carefully clean the surface

areas using a misture of 50% water and 50%
isopropyl alcohol. Make sure all adhesive is
removed from the pedal and pedal arm assembly
and make sure that surface areas are perfectly
dried.
4.
Apply four(4) pieces of double-back adhesive tape

the pedal arm assembly as shown.
5.
Reinstall the pedal and apply 30-40 psi clamp

pressure for approximately 60 seconds or longer.
26
Pedal
Arm
Assembly
Double-back
Adhesive
Tape (4 pieces)
on
How To... Set Jumpers on CSAFE Card

1.
Remove six(6) screws from the FRONT COVER and

separate the front cover halves.
2.
Set jumpers according to chart below.
3.
Reinstall FRONT COVERS.
Front Cover
Frame, Bottom
Networking Cable
JUMPER SETTINGS
JW2
JW3
JW4
JW5
JW6
OUT
IN
OUT
OUT
OUT
IN
CSAFE Card
Mounting Bracket
Front Cover
Section III
JW1
27
NOTES:
28
SECTION IV
Section IV
ELECTRONICS OVERVIEW
AND
WIRING BLOCK DIAGRAMS
ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD
Connector P5 (Not applicable on

9500 with Display Lock only)
Functional Description:
The Display Console Board is designed to
work in conjunction with the Alternator
Control Board. It reads the keypad input for
changes or updates by the user, and
refreshes the status LEDs, data display,
and profile display matrix.
Display EPROM
Connector P7
Connector P2
Connector and Pin Functions

Connector
Location
Pin
Functional Description
P1 is a 17 pin, ribbon connector

that connects to the Overlay
Board
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Ground
Strobe
Strobe
Return
Strobe
Return
Strobe
Return
Strobe
Return
Ground
Start
Strobe
Return
Strobe
Return
Ground
P2 is a 10 pin connects to the

Alternator Control Board
1
2
3
4
5
6
7
8
9
10
VSYS POWER CONTROL (7-8VDC)

RPM (5VDC)
GROUND
LOAD
VBAT (6 VDC)
NOT USED
FLDCMD
START
VBAT (6VDC)
VBAT (6VDC)
Connector P1
ELECTRONICS OVERVIEW - DISPLAY CONSOLE BOARD Continued
P5 is an 8 pin connector that

connects the Life Pulse Board to
the Console Board
Note: Not applicable on

CT9500 with Display Lock
feature.
P7 is a 3 pin connector that

comes from the Polar connector
Location
Pin
1
2
3
4
5
6
7
8
HR-ENABLE (3.8 VDC)

KEY
VSYS (7-8 VDC)
VSYS (7-8 VDC)
GROUND
GROUND
HR-D0 (4.7 VDC)
HR-DI (4.7 VDC)
1
2
3
+VCC (5VDC)
SIGNAL
GROUND
Section IV
Connector
ELECTRONICS OVERVIEW - POWER CONTROL BOARD

TP1
TP4
The Power Control Board is

designed to regulate the
alternator voltage by
modulating the field current. It
regulates the pass current
(RPM signal) from the
Alternator to the Console, and
the pass current from the
alternator to the load resistor
while providing supply voltage
for the console.
TP2
Connector P2
Connector P3
Connector P1
Connector and Pin Functions

Connector
Location
P1 is a Molex 11 pin connector

that connects to the Console
Pin
1
2
3
4
6
7
8
9
10
11
START
GND
KEY
VSYS
LOADCMD
RPM
START
VBAT (6VDC)
GND
P2 is a 12 pin connector that

connects to the Alternator and
Power Resistor
1
2
3
4
5
6
7
8
9
10
11
12
GND
GND
GND
RPM
GND
FIELD
LOAD
LOAD
LOAD
VALT (10VDC)
VALT (10VDC)
LOAD
P3 is 4 pin connector (not used)
1
2
3
4
5
VSYS (7-8VDC)
Keyed
VSYS (7-8VDC)
GND
GND
N/A
GND
TP3
ELECTRONICS OVERVIEW ALTERNATOR
The 12 volt, 35 amp Alternator is designed to provide electrical power to the product, supply load resistance while
providing electrical power, and provide the RPM signal from the AC TAP to the Alternator Control Board.
Connector Locations:
AC TAP TERMINAL
OUTPUT TERMINAL
IT AT
EXC
IO N
FIELD TERMINALS R ETUR N
Section IV
GROUND TERMINAL
WIRING BLOCK DIAGRAM FOR LC9500HR
Section IV
NOTES:
SECTION V
Section V
PARTS IDENTIFICATION
MODEL IDENTIFICATION and SERIAL NUMBER LOCATION
Model / Serial number
Life Fitness Model 8500 Cross-Trainer
MODEL CT85-0100-01
SN 100000-Up
Console
AK61-00026-0001 Eng/Met
Overlay
AK61-00025-0001 Eng/Met
Main Cable
AK61-00015-0000
Console Spacer
0K61-05009-0000
Console Post Assembly

AK61-00500-0005
Decal
0K61-01200-0000
Grips(2)
0K61-06003-0000
Upper Arm (RT)
AK61-00460-0002
Boot(2)
0K61-06000-0000
Upper Arm (LT)

AK61-00460-0003
Front Post Cover

0K61-06010-0002
Rear Post Cover
0K61-06020-0002
Install Hardware
AK61-00040-0000
Instruction Bag
AK61-00042-0000
Endcap (2)
0K61-06001-0001
Pedal Arm (RT)

GK61-00002-0006
Pedal Arm Covers (RT)

0K61-06320-0000 Inside
AK61-00019-0002 Outside
Lower Arm Assembly(2)

GK61-00002-0022
Rear Cover (RT)

GK61-00002-0014
Clevis Covers Assembly(2)

AK61-00062-0000)
Grommet
0017-00042-0754
Plug (2)
0K14-01384-0000
Front Cover (RT)

0K61-06200-0000
Front Cover (LT)
0K61-06210-0000
Rear Cover (LT)

GK61-00002-0013
Pedal Arm (LT)
GK61-00002-0005
Pedal Arm Covers(LT)

0K61-06300-0000 Inside
AK61-00019-0000 Outside
0K61-01226-0002(2) Decal
Endcap (4)
0K61-06002-0001
Wheel(2)
GK61-00002-0011
Cap
0017-00012-1066
Leveler(4)
AK61-00035-0000
3
Section V
Grips(2)
0K61-05008-0000
MODEL CT85-0100-01
SN 100000-Up
Tie Rod (2)

GK61-00002-0020
Bolt
0017-00101-1646
Nut
0017-00103-0137
Sleeve
0K61-01076-0000
Arm Extension
0K61-03004-0000
Bolt
0017-00101-1645
Anit Lift Bracket (2)

0K61-04114-0000
Bolts (4)
0017-00101-1645
Roller Kit
GK61-00002-0027
Drive Belt
0K61-02700-0000
Alternator w/ Flywheel
AK61-00250-0001
Alternator
0017-00009-0841
Drive Pulley Assembly

AK61-00230-0001
Pulley
0K61-02409-0000
Magnet
AK61-00044-0001
Pillow Block Bearings (2)
0K53-01181-0000
Pedal (2)
GK61-00002-0010
Tape (4)
0K61-04115-0002
Frame Cover
GK61-00002-0003
Tape
0K61-04115-0002
Battery
0017-00003-0685
Alternator Belt
0K53-01184-0000
Intermediate
Pulley Assembly
AK61-00061-0000
Grommet (14)
0017-00042-0754
(2)
Resistor Bracket Assembly

GK61-00002-0024
Alternator Cable
AK61-00017-0000
PCB
GK61-00002-0023
Stand Off (4)
0017-00042-0320
Nut (4)
0017-00103-0008
Crank Arm Assembly

GK61-00002-0021
Nut
0017-00103-0025
Bolt
0017-00101-1606
Keyway
0K53-01122-0000
Allen Screw
0017-00101-0333
MODEL CT91-0100-01
SN 100000-Up

AK61-00500-0004
Decal
0K61-01200-0000
Console- AK61-00024-0001 Eng/Met

Overlay - AK61-00023-0001 Eng/Met
Main Cable - AK61-00015-0000
Polar Cable - AK61-00014-0000
Console Spacer - 0K61-05009-0000
Accessory Tray - GK61-00002-0002
Grips(2)
0K61-06003-0000
Upper Arm (RT)
AK61-00460-0002
Boot(2)
0K61-06000-0000
Upper Arm (LT)

AK61-00460-0003
Front Post Cover

0K61-06010-0002
Rear Post Cover
0K61-06020-0002
Polar Receiver
SK40-00045-0001
Foam Isolator
0K36-01059-0002
Grips(2)
0K61-05008-0000
Install Hardware
AK61-00040-0000
Instruction Bag
AK61-00043-0000
Pedal Arm (RT)

GK61-00002-0006
Endcap(2)
0K61-06001-0001

0K61-06320-0001 Inside
AK61-00056-0001 Outside
Rear Cover (RT)
AK61-00002-0016
Clevis Covers Assembly(2)

AK61-00062-0000
Grommet
0017-00042-0754
Plug (2)
0K14-01384-0000
Front Cover (RT)

0K61-06250-0000
Front Cover (LT)
0K61-06240-0000
Pedal Arm (LT)

GK61-00002-0005
Pedal Arm Covers (LT)

0K61-06300-0001 Inside
AK61-00056-0002 Outside
Decal
0K61-01230-0001(2)
Section V

GK61-00002-0022
Rear Cover (LT)

AK61-00002-0015
Endcap(4)
0K61-06002-0001
Wheel(2)
GK61-00002-0011
Leveler(4)
AK61-00035-0000
5
MODEL CT91-0100-01
SN 100000-Up
Tie Rod (2)

GK61-00002-0020
Arm Extension
0K61-03004-0000
Bolt
0017-00101-1645
Bolt
0017-00101-1646
Nut
0017-00103-0137
Sleeve
0K61-01076-0000
Anti Lift Bracket (2)

0K61-04114-0000
Bolts (4)
0017-00101-1645
Pedal (2)
GK61-00002-0010
Tape (4)
0K61-04115-0002
Roller Kit
GK61-00002-0027
Drive Belt
0K61-02700-0000
AK61-00250-0001
Alternator
0017-00009-0841

Frame Cover
AK61-00230-0001
GK61-00002-0019
Pulley
Tape
0K61-02409-0000
0K61-04115-0002
Magnet
AK61-00044-0001
Battery
0017-00003-0685
0K53-01181-0000
Alternator Belt
0K53-01184-0000
Intermediate
Pulley Assembly
AK61-00061-0000
Grommet (14)
0017-00042-0754
(2)

GK61-00002-0024
Alternator Cable
AK61-00017-0000
PCB
GK61-00002-0023
Stand Off (4)
0017-00042-0320
Nut (4)
0017-00103-0008
Crank Arm Assembly

GK61-00002-0021
Nut
0017-00103-0025
Bolt
0017-00101-1606
Keyway
0K53-01122-0000
Allen Screws
0017-00101-0333
Life Fitness Model 9500 Cross-Trainers
MODEL CT95-0100-15
SN 100000-Up
Polar Cable - AK61-00014-0000

Main Cable - AK61-00015-0000
Overlay - AK61-00054-0001 Eng/Met
Console- AK61-00053-0001 Eng/Met
HR Cable - AK61-00052-0002
Accessory Tray - GK61-00002-0002

AK61-00500-0004
Decal
0K61-01200-0000
Upper Arm (RT)

AK61-00048-00012
Front Post Cover
0K61-06350-0002
Rear Post Cover
0K61-06351-0002
Polar Receiver
SK40-00045-0001
Foam Insulator
0K36-01059-0002
Upper Arm (LT)

AK61-00048-0002
Grips(2)
0K61-05008-0000
Instruction Bag
Ak61-00049-0000
Install Hardware
AK61-00050-0000

0K61-06320-0001 Inside
AK61-00018-0003 Outside
Pedal Arm (RT)
GK61-00002-0006
Front Boot Cover

0K61-06340-0002
Rear Boot Cover
0K61-06341-0002
Pedal Arm (LT)

GK61-00002-0005

0K61-06300-0001 Inside
AK61-00018-0001 Outside
Decal
0K61-01222-0001(2)
Section V
Rear Cover (RT)

AK61-00002-0016

GK61-00002-0019
Front Cover (RT)

0K61-06250-0000
Front Cover (LT)
0K61-06240-0000
Plug (2)
0K14-01384-0000
Rear Cover (LT)

AK61-00002-0015
Endcap (4)
0K61-06002-0001
Wheel(2)
GK61-00002-0011
Leveler(4)
AK61-00035-0000
MODEL CT95-0100-15
SN 100000-Up
Arm Extension
0K61-03004-0000
Bolt
0017-00101-1645
Tie Rod (2)

GK61-00002-0020
Bolt
0017-00101-1646
Nut
0017-00103-0137
Sleeve
0K61-01076-0000
Pedal (2)
GK61-00002-0010
Tape (4)
0K61-04115-0002

0K61-04114-0000
Bolts (4)
0017-00101-1645
Roller (2)
0K61-00002-0027
Drive Belt
0K61-02700-0000
AK61-00250-0001
Alternator
0017-00009-0841

AK61-00230-0001
Pulley
0K61-02409-0000
Magnet
AK61-00044-0001
Frame Cover
GK61-00002-0019
Tape
0K61-04115-0002

0K53-01181-0000
Battery
0017-00003-0685
Alternator Belt
0K53-01184-0000
Intermediate
Pulley Assembly
AK61-00061-0000

GK61-00002-0024
Alternator Cable
AK61-00017-0000
Grommet (14)
0017-00042-0754
PCB
GK61-00002-0023
Stand Off (4)
0017-00042-0320
Nut (4)
0017-00103-0008
Crank Arm Assembly

GK61-00002-0021
Nut
0017-00103-0025
Bolt
0017-00101-1606
Keyway
0K53-01122-0000
Allen Screw
0017-00101-0333
MODEL CT95-0100-17
SN 103198-Up
Polar Cable
AK61-00014-0000
Main Cable
AK61-00015-0000
Overlay
AK61-00076-0001 Eng/Met
Console
AK61-00075-0001 Eng/Met
HR Cable
AK61-00052-0002
Accessory Tray
GK61-00002-0018

AK61-00500-0010
Decal
0K61-01200-0000
Upper Arm (RT)

AK61-00048-00012
Front Post Cover
0K61-06350-0002
Rear Post Cover
0K61-06351-0002
Polar Receiver
SK40-00045-0001
Foam Insulator
0K36-01059-0002
Upper Arm (LT)

AK61-00048-0002
Grips(2)
0K61-05008-0000
Install Hardware
AK61-00050-0000
Instruction Bag
AK61-00049-0000

0K61-06320-0001 Inside
AK61-00018-0003 Outside
Pedal Arm (RT)
GK61-00002-0006
Front Boot Cover

0K61-06340-0002
Rear Boot Cover
0K61-06341-0002
Pedal Arm (LT)

GK61-00002-0005

0K61-06300-0001Inside
AK61-00018-0001Outside
Decal
0K61-01222-0001(2)
Section V
Rear Cover (RT)

AK61-00002-0016

GK61-00002-0019
Front Cover (RT)

0K61-06250-0000
Front Cover (LT)
0K61-06240-0000
Plug (2)
0K14-01384-0000
Rear Cover (LT)

AK61-00002-0015
Endcap (4)
0K61-06002-0001
Wheel(2)
GK61-00002-0011
Leveler(4)
AK61-00035-0000
MODEL CT95-0100-17
SN 103198-Up
Tie Rod (2)

GK61-00002-0020
Bolt
0017-00101-1646
Nut
0017-00103-0137
Sleeve
0K61-01076-0000
Arm Extension
0K61-03004-0000
Bolt
0017-00101-1645
Pedal (2)
GK61-00002-0010
Tape (4)
0K61-04115-0002

0K61-04114-0000
Bolts (4)
0017-00101-1645
Roller Kit
GK61-00002-0027
Drive Belt
0K61-02700-0000
AK61-00250-0001
Alternator
0017-00009-0841

AK61-00230-0001
Pulley
0K61-02409-0000
Magnet
AK61-00044-0001
Frame Cover
GK61-00002-0019
Tape
0K61-04115-0002

0K53-01181-0000
Battery
0017-00003-0685
Alternator Belt
0K53-01184-0000
Intermediate
Pulley Assembly
AK61-00061-0000
Grommet (14)
0017-00042-0754
(2)

GK61-00002-0024
Alternator Cable
AK61-00017-0000
10
PCB
GK61-00002-0023
Stand Off (4)
0017-00042-0320
Nut (4)
0017-00103-0008
Crank Arm Assembly

GK61-00002-0021
Nut
0017-00103-0025
Bolt
0017-00101-1606
Keyway
0K53-01122-0000
Allen Screw
0017-00101-0333
Section V
NOTES:
11
SECTION VI
Section VI
MISCELLANEOUS INFORMATION
PREVENTIVE MAINTENANCE TIPS
Preventive Maintenance Schedule

DAILY
MONTHLY
BI-ANNUALLY
Housing
Inside
Outside
Clean
Clean
Power Control
Heatsink
Clean
Connectors
Inspect
Board
Inspect
Console Assembly
Overlay
Clean
Mounting Bolts
Inspect
Connectors
Inspect
Alternator
Belt Tension
Inspect
Brushes
Inspect
Flywheel
Clean/Inspect
Mechanical
Main Drive Belt
Inspect
Oil Light Bearings

Pedals
Drive Pulley
Inspect and lube with

non-detergent oil
Clean
Clean/Inspect
INSTALLATION INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS!
DO NOT locate the Cross-Trainer outdoors, near swimming pools, or in areas of high humidity.
DO NOT operate your Cross-Trainer if it has been dropped, damaged, or even partially immersed
in water. Contact Life Fitness Customer Support Services at the number in the Operation Manual.
DO NOT locate the Cross-Trainer any closer than 30 inches ( 76 cm ) to a television set.
DO NOT locate additional Cross-Trainers any closer than a minimum of 42 inches (107 cm) from
center to center to avoid interference (cross talk) between Heart Rate monitors.
DO keep the area around your Cross-Trainer clear of any obstructions, including walls and furniture.
DO verify the contents of the delivery carton against the accompanying Parts Listing prior to setting
the cartons and shipping material aside. If any parts are missing, contact Life Fitness Customer
Support Services at the number listed in the Operation Manual. Save the shipping cartons in case of
return.
DO read the entire Operation Manual prior to attempting to operate this machine as this is essential
for proper use.
Section VI
INSTALLATION INSTRUCTIONS
TOOLS REQUIRED FOR ASSEMBLY... Magnetic #2 Bit Phillips Screwdriver, 5/16 & 3/16 Hex Key
Wrenches, 1/2" Open End Wrench
Parts List
1
Hex Socket Head Cap Screw
Qty: 8
3/8-16 x 1
0017-00101-1148
Phillips Pan Head Screw

#8-18 x 3/4"
(Model 9100) Qty: 14

(Model 9500HR)
Qty: 18
Qty: 1
Back Monocolumn Cover
0K61-06020-0002 (Model 9100)
0K61-06010-0002 (Model 9100)
0K61-06350-0002 (Model 9500HR)
0K61-06351-0002 (Model 9500HR)
Console Support Assembly
Qty: 1
Qty: 1
Flat Washer
Qty: 2
0017-00104-0192
Left Front Cover
Qty: 1
10
0K61-06240-0000
11
Qty: 1
AK61-00053-0001 (Model 9500HR)
Front Monocolumn Cover
AK61-00500-0004
9
Console Assembly
AK61-00024-0001 (Model 9100)
0017-00101-1242
5
Qty: 4
#8-16 x 3/4"
0017-00101-1645
3
Phillips Pan Head Screw
Right Front Cover
Qty: 1
0K61-06250-0000
Left User Arm Assembly
12
Qty: 1
Right User Arm Assembly
Qty: 1
AK61-00460-0002 (Model 9100)
AK61-00460-0003 (Model 9100)
AK61-00048-0001 (Model 9500HR)
AK61-00048-0002 (Model 9500HR)

13
Front Rocker Cover
Qty: 2
14
0K61-06340-0002 (Model 9500HR Only)

15
Qty: 2
0K61-06341-0002 (Model 9500HR Only)
Foam Isolator (Polar Receiver)
Qty: 1
16
0K36-01059-0002
17
Back Rocker Cover

Polar Receiver
Qty: 1
AK40-00045-0001
Accessory Tray
Qty: 1
18
Button Head Cap Screw
Qty: 4
5/16-18 x 5/8"
AK61-00045-0002
19
0017-00101-1647
Acorn Nut
Qty: 4
20
Console Spacer
Qty: 1
5/16-18
0017-00103-0287
21
0K61-05009-0000
Front Clevis Cover
0K61-06352-0002
23
Internal Lock Washer
Qty: 2
22
Back Clevis Cover
0K61-06353-0002
Qty: 2
Qty: 6
0017-00104-0450 (Model 9500HR Only)
18
1
4
19
23
Step 1
Before proceeding, familiarize yourself with the parts of
the Cross-Trainer and make sure that you have received
all the items described in the Parts List.
3
9
Step 2
Locate the left and right FRONT COVER (#9, #10).
Using two PHILLIPS PAN HEAD SCREWS (#3), mount
the USER LEFT FRONT COVER (#9) to the FRAME
(A). Attach the USER RIGHT FRONT COVER (#10) to
the FRAME in the same manner using two PHILLIPS
PAN HEAD SCREWS (#3). Secure the tops of the
FRONT COVERS together using two PHILLIPS PAN
HEAD SCREWS (#3).
3
A
10
11
12
D
D
Step 3
(Model 9100 Only)
Locate the LEFT USER ARM (#11). Secure the LEFT
USER ARM to the LEFT ROCKER ARM (B) using three
HEX SOCKET HEAD CAP SCREWS (#1). Repeat the
procedure for the RIGHT USER ARM (#12) and RIGHT
ROCKER ARM (C). Tighten all screws securely. Slide the
BOOT COVERS (D) located on the user arms down over
the mounting plates.
(Model 9500HR Only)

Locate the LEFT USER ARM (#11). Snap the 2-PIN
CONNECTOR (2PA) located at the bottom of the LEFT
USER ARM into the 2-PIN CONNECTOR (2PB)
positioned at the top of the LEFT ROCKER ARM (B).
Feed the connectors and excess cable up into the LEFT
USER ARM. Secure the LEFT USER ARM to the LEFT
ROCKER ARM using three HEX SOCKET HEAD CAP
SCREWS (#1) and INTERNAL LOCK WASHERS
(#23). Repeat the procedure for the RIGHT USER ARM
(#12) and RIGHT ROCKER ARM (C). Tighten all
screws securely.
12
11
23
1
2PA
2PB
Section VI
C
CAUTION: BE CAREFUL NOT TO PINCH THE WIRE
HARNESSES WHEN ASSEMBLING THE USER
ARMS (#11 & #12) TO THE ROCKER ARMS (B & C)
(Model 9500HR Only).
B
Model 9500HR Shown
Step 4
Detach and unwrap the WIRE HARNESS (E) (10P,
3P, (4P 9500HR Only)) located at the top of the
MONOCOLUMN (F). Holding the CONSOLE
SUPPORT ASSEMBLY (#7) with the handgrips
facing upward, feed the WIRE HARNESS up
through the neck and out the top access hole.
Carefully lower the CONSOLE SUPPORT
ASSEMBLY into the MONOCOLUMN.
3P
10P
20
17
4P
CAUTION: BE CAREFUL NOT TO PINCH THE

WIRE HARNESS (E) WHEN ASSEMBLING THE
CONSOLE SUPPORT ASSEMBLY (#7) TO THE
MONOCOLUMN (F).
18
Step 5
Using two HEX SOCKET HEAD CAP SCREWS
(#1) and two FLAT WASHERS (#8), secure the
CONSOLE SUPPORT ASSEMBLY (#7) to the
MONOCOLUMN (F). Tighten the screws securely.
Step 6
Locate the ACCESSORY TRAY (#17). Feed the
WIRE HARNESS (E) through the center access
hole. Place the ACCESSORY TRAY on the
CONSOLE SUPPORT ASSEMBLY (#7) as shown.
Using four BUTTON HEAD CAP SCREWS (#18)
and ACORN NUTS (#19), secure the
ACCESSORY TRAY to the CONSOLE SUPPORT
ASSEMBLY through the large mounting holes.
Tighten the screws securely.
Step 7
Attach the 3-PIN (3P) and 10-PIN (10P)
CONNECTORS to the corresponding jacks on the
back of the CONSOLE ASSEMBLY (#4).
(Model 9500HR Only)
19
7
2
8
F
Model 9500HR Shown
Attach the 4-PIN (4P) CONNECTOR to the corresponding jack on the back of the CONSOLE ASSEMBLY
(#4).
Step 8
Place the CONSOLE ASSEMBLY SPACER (#20) onto the CONSOLE SUPPORT ASSEMBLY (#7). Align
the mounting holes in the CONSOLE ASSEMBLY SPACER with those in the CONSOLE SUPPORT
ASSEMBLY.
Step 9
Feed any excess WIRE HARNESS (E) down into the CONSOLE SUPPORT ASSEMBLY (#7). Secure
the CONSOLE ASSEMBLY (#4) to the CONSOLE SUPPORT ASSEMBLY using four PHILLIPS PAN
HEAD SCREWS (#2). Tighten the screws securely.
CAUTION: DO NOT OVER-TIGHTEN THE PHILLIPS HEAD PAN SCREWS (#2).
CAUTION: BE CAREFUL NOT TO PINCH THE WIRE HARNESS (E) WHEN ASSEMBLING THE
CONSOLE ASSEMBLY (#4) TO THE CONSOLE SUPPORT ASSEMBLY (#7).
Step 10
Locate the POLAR RECEIVER (#16). Slide the FOAM
ISOLATOR (#15) over the POLAR RECEIVER.
Remove the POLAR RECEIVER JACK (G) located at
the front of the MONOCOLUMN (F) near the PIVOT
SHAFT (H) from the tape and plug the POLAR
RECEIVER into the POLAR RECEIVER JACK.
5
G
Step 11
Locate the front and back MONOCOLUMN COVERS
(#5 & #6). With the wire positioned on top, carefully
insert the POLAR RECEIVER (#16) between the
vertical ribs located inside the BACK MONOCOLUMN
COVER (#6).
Place the BACK MONOCOLUMN COVER (#6) over
the PIVOT SHAFT (H) at the top of the
MONOCOLUMN (F).
16
H
15
6
3
F
Model 9100 Shown
NOTE: THE POLAR RECEIVER WIRE MUST BE POSITIONED ON TOP WHEN INSERTED
INTO THE REAR MONOCOLUMN COVER (#6).
Step 12 (Model 9100 Only)
Place the FRONT MONOCOLUMN COVER (#5) on the opposite side of the BACK MONOCOLUMN
COVER (#6) to cover the PIVOT SHAFT (G) and CONSOLE SUPPORT ASSEMBLY MOUNTING
SCREWS. Use four PHILLIPS PAN HEAD SCREWS (#3) to secure the MONOCOLUMN COVERS
together. Tighten the screws securely.
Step 13 (Model 9500HR Only)

Place the FRONT MONOCOLUMN COVER (#5) on the opposite side of the BACK MONOCOLUMN
COVER (#6) to cover the PIVOT SHAFT (G) and CONSOLE SUPPORT ASSEMBLY MOUNTING
SCREWS. Interlock the top tabs and use two PHILLIPS PAN HEAD SCREWS (#3) to secure the bottoms
of MONOCOLUMN COVERS together. Tighten the screws securely.
CAUTION: DO NOT OVER-TIGHTEN THE PHILLIPS PAN HEAD SCREWS (#3).
14
5
16
H
15
6
3
14
Locate one FRONT ROCKER COVER

(#13) and one BACK ROCKER COVER
(#14). Position the FRONT ROCKER
COVER over the user side of the left end
of the PIVOT SHAFT (F) (as shown)
making sure that it interlocks with the
MONOCOLUMN COVERS (#5 & #6).
Place the BACK ROCKER COVER over
the opposite side of the left end of the
PIVOT SHAFT in the same manner.
Secure the covers using three PHILLIPS
PAN HEAD SCREWS (#3). Repeat the
procedure reversing front and back for the
user right end of the pivot shaft.
13
Model 9500HR Shown
3
7
Section VI
Step 14 (Model 9500HR Only)

13
Step 15
Rotate the LEFT ROCKER ARM (B) to its fullest rear position.
Locate one FRONT CLEVIS COVER (#21) and one BACK
CLEVIS COVER (#22). Position the BACK CLEVIS COVER at
the LEFT CLEVIS JOINT (J). Hook the bottom tabs of the
FRONT CLEVIS COVER into the bottom of the BACK CLEVIS
COVER and pivot the FRONT CLEVIS COVER upward to fully
meet the BACK CLEVIS COVER. Secure the CLEVIS
COVERS to the LEFT ROCKER ARM using two PHILLIPS
PAN HEAD SCREWS (#3). Tighten the screws securely.
21
22
PRE-OPERATION CHECKLIST
4 Ensure that all fasteners are tight.
4 Make sure the CROSS-TRAINER is properly leveled and stable.
(Refer to the Operation Manual)
4 Ensure that the Leveler Jam Nuts are tight.

(Refer to the Operation Manual)
4 Read the entire Operation Manual before using the Cross-Trainer.
Before attempting to operate your Cross-Trainer, it is imperative that you familiarize yourself with the
contents of the Operation Manual. If your Cross-Trainer does not respond as described in the
OPERATION MANUAL, contact the nearest Life Fitness service center as listed in the Operation Manual.
UNPACKAGING INSTRUCTIONS
Step 1
Remove all staples from the corrugated shipping container and fold down the four sides of the base tray (A).
Step 2
Lift and open the top flaps of the shipping container sleeve (B). Lift and remove the two front support posts (C).
Step 3
With the help of another person, carefully lift the shipping container sleeve (B) up and off of the base tray (A) and over
the Cross-Trainer (D). Remove the ship kit box (E) from the Cross-Trainer and set aside. Remove the remaining corner
posts (F) and ship kit support (G).
Step 4
Using a screwdriver, remove the rear
locator pad (H) from the base tray (A).
Step 5
Carefully lift the front of the unit and slowly
roll the unit backward beyond the flattened
base tray.
Step 6
Follow the Installation Instructions
included in the parts bag to complete the
assembly of your Cross-Trainer.
Ship Kit Contents:
Left & Right User Arms
Console Support Assembly
Left & Right Front Covers
Display Console
Front & Back Monocolumn Covers
Hardware Kit
Installation Instructions
Polar Receiver Kit
( 9100 / 9500HRR Only )

Reading Rack Assembly
( 9500HRR Only )
Heart Rate Monocolumn Covers
H
F
( 5500HR Only )
Line Cord (International Only)
Power Supply
Polar Transmitter Kit
Section VI
IMPORTANT
SAVE YOUR PACKING MATERIALS IN CASE OF
9
COMMUNICATING BY FAX
If you would like to submit a parts order, or if you need help troubleshooting
a problem, we have included, for your convenience, a FAX form on the
following page. Simply make a copy (or copies) of the FAX sheet and fill in
the necessary information. You may FAX us at any time, 24 hours a day, to
either of the numbers shown. A Life Fitness service representative will
process your order, or respond to your problem, as quickly as possible.
10
CUSTOMER SUPPORT SERVICES

PARTS ORDER
SALE
( IF BOTH
PLEASE INDICATE )
PRODUCT TROUBLESHOOTING
WARRANTY
NAME:
CUSTOMER NO:
DATE:
PHONE:
FAX:
CONTACT NAME:
METHOD OF SHIPMENT:
1 DAY
2 DAY
GROUND
PARTS ORDER FORM

ITEM NO.
1
PART NUMBER
DESCRIPTION
QUANTITY
2
3
4
5
6
PRODUCT TROUBLESHOOTING
PRODUCT NAME:
SERIAL NO.
DETAILED DESCRIPTION OF PROBLEM:
PRODUCT NAME:
SERIAL NO.
DETAILED DESCRIPTION OF PROBLEM:
TIME COMPLETED:
TECHNICIAN NAME:
Section VI
TIME RECEIVED:
11
CUSTOMER SUPPORT SERVICES
10601 W. Belmont Ave., Franklin Park IL 60131 PHONE (800) 351-3737 Toll Free or (708) 451-0036
FAX (800) 216-8893 Toll-Free or (708) 288-3702
12
NOTES:
13

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Models 8500, 9100, and 9500HR

Total Body Cross-Trainers with Rear Drive System

Customer Support Services

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

LIFE FITNESS - CUSTOMER SUPPORT SERVICES

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

Electrical plugs used to connect wiring into electrical component.

Electronic board for making settings and monitoring physical output.

Disgital system processing.

Electrically errasible programmable read only memory.

Electrically errasible read only memory.

Load duty cycle.

Light emitting diode used to show a state of operation.

Heart rate sensors on hand grips.

Power control board regulates voltage to alternator, console, and battery.

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

The area where all the drive components reside.

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

TABLE OF CONTENTS Continued

Life Fitness Models 8500, 9100, and 9500HR Cross-Trainers

TABLE OF CONTENTS Continued

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Life Fitness Model 8500, 9100, and 9500HR Cross-Trainers

Loosen the pillow block bearings,

Dirt build up in pedal tracks.

Clean and remove dirt build up.

Rear roller wheels frozen.

Clean and lubricate with non

Link cover contacting rear cover.

Reposition rear cover(s) or replace.

Excessive disk wobble.

Make sure no weld interference

Faulty intermediate shaft assembly.

Replace intermediate shaft assy.

Faulty pillow block.

Replace pillow blocks on crankshaft.

Relieve tension on alternator, spin

Bearings at pivot points are out of

Clean all sleeves in the linkage pivot

Setscrews or crankarm bolt in

Loosen setscrew and clamping

Small extension arm bolt loose.

Replace small extension arm kit.

Faulty link bearings.

Replace link assembly.

Link mounting loose.

Clean, lubricate, and retighten.

Excessive end play in rocker arms.

Adjust collars as necessary to take

Pedal lever vibrates or squeaks during

Align pedal lever. See How To

Pedal tape not adhering properly.

See How To Replace Pedal Lever

Drive Belt slipping.

Loose or worn belt.

Check belt tension using a J10 belt

Upper Arms feel loose.

Bolts that connect the upper and

Adjust and tighten to a torque of 3035 ft lb.

Front to back play in pedal lever.

Check for front to back movement in