Life Fitness 4500HR Service Manual
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Life Fitness 4500HR Service Manual

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NET PRICE: $
Model 4500HR Treadmill
After Market Services
SERVICE MANUAL

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Summary of Contents for Life Fitness 4500HR

  • Page 1 NET PRICE: $ Model 4500HR Treadmill After Market Services SERVICE MANUAL...
  • Page 2 Certificate No. 1,400,502, issued July 8, 1986. FlexDeck, Zone Trainer and Heart Rate Zone Training are trademarks of Life Fitness. Any use of these trademarks, without the express written consent of Life Fitness, is forbidden. U.S. Patent Numbers 3,767,195 and 4,358,105.

  • Page 3: Section I

    A form to order by FAX has also been included in Section IV for your convenience. To order a part, call Life Fitness After Market Services any Monday through Friday from 8:00 AM to 6:00 PM ( C.S.T.). When you place a call, in order to speed our response to your particular situation, please have the following information available for the customer service phone technician who will be prepared to assist you: 1.

  • Page 4: Table Of Contents

    INTRODUCTION (How to use this Service Manual) TABLE OF CONTENTS SECTION I PAGE TROUBLESHOOTING GUIDES THEORY OF OPERATION ............................1 NO POWER .................................. 2 NOISY TREADMILL..............................3 STRIDING BELT ................................4 UNIT RESETS RANDOMLY ............................5 DISPLAY DOES NOT ILLUMINATE OR RESPOND TO INPUT ................6 UNIT WILL NOT ELEVATE ............................

  • Page 5: Theory Of Operation

    Life Fitness Model 4500HR Treadmill THEORY OF OPERATION The operational functions of the Life Fitness Model 4500HR Treadmill are accomplished by four main components: the Control Board, the Display Console, the Drive Motor and the Lift Actuator. The Treadmill user and the control board provide input to the display console.

  • Page 6: Power

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE NO POWER Symptom: Malfunction Probable Cause Corrective Action Turn unit On. On/off switch No Power Insufficient power source Plug treadmill into power source with proper electrical requirements. (See Operation Manual) Line cord improperly seated in Inspect power connection at outlet.

  • Page 7: Noisy Treadmill

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE NOISY TREADMILL Symptom: Malfunction Probable Cause Corrective Action Rubbing sound from Foreign objects may be stuck Inspect underneath Belt and Machine. under the machine beneath machine Remove any debris or accumulation. Rubbing sound from Striding Belt not tracking Adjust Striding Belt tracking.

  • Page 8: Striding Belt

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE STRIDING BELT Symptom: Corrective Action Malfunction Probable Cause Insufficient power source Plug treadmill into power source with proper Striding Belt will not move electrical requirements. (See Operation Manual) Faulty Control Board Replace Control Board High amount of friction Start unit with no one on it at 3.5 mph and 5%...

  • Page 9: Unit Resets Randomly

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE UNIT RESETS RANDOMLY Symptom: Malfunction Probable Cause Corrective Action Unit Resets Randomly Insufficient Power Source Plug Treadmill into power source with proper electrical requirements. (See Operational Manual) Damaged Line Cord Replace Line Cord.

  • Page 10: Display Does Not Illuminate Or Respond To Input

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE DISPLAY DOES NOT ILLUMINATE OR RESPOND TO INPUT Symptom: Malfunction Probable Cause Corrective Action Insufficient power source. Plug Treadmill into power source with proper Display will not illuminate electrical requirements. (See Operation when machine is turned on.

  • Page 11: Unit Will Not Elevate

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE UNIT WILL NOT ELEVATE Symptom: Malfunction Probable Cause Corrective Action Unit will not elevate Line Cord is crossed over lifting Check position of Line Cord placement. assembly Faulty Lift Actuator (limits) Perform Lift Test (See Diagnostics).

  • Page 12: Error Display Messages

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE ERROR DISPLAY MESSAGES Symptom: Malfunction Probable Cause Corrective Action ERROR MESSAGES: Check all electrical connections. Bad connection to Opto Speed START UP Sensor (Occurs when the Striding Belt, upon start up, will speed up at a high rate) Adjust or replace Opto Speed Sensor.

  • Page 13: Heartrate Does Not Respond

    Life Fitness Model 4500HR Treadmill TROUBLESHOOTING GUIDE HEARTRATE DOES NOT RESPOND Symptom: Malfunction Probable Cause Corrective Action Check all electrical connections. Heart Rate system does not Heart Rate cable not connected respond Secure connection at Receiver Loose connection at Receiver Secure connection at Console and Handlebar.
  • Page 14 Life Fitness Model 4500HR Treadmill NOTES:...
  • Page 15 Life Fitness Model 4500HR Treadmill DIAGNOSTIC TESTS PURPOSE: This Section describes the test procedures for the Life Fitness 4500HR Treadmill Display Console Board including the Heart Rate feature. SCOPE: Diagnostic procedures will test the Display Console Board as used in the final Treadmill assembly. These procedures will insure proper functioning of the Console LED’s, Keys and Displays as well as identify the Console...

  • Page 16: Diagnostic Tests

    Life Fitness Model 4500HR Treadmill DIAGNOSTIC TESTS THE SPEED DOWN t KEY IS USED FOR THE FOLLOWING TESTING INFORMATION: ⇒ CHECK THE DISPLAY/KEYPAD FUNCTIONS ⇒ REVIEW STATISTICS ⇒ IDENTIFY SOFTWARE VERSION USE THE ENTER KEY TO ADVANCE THROUGH THE TEST.
  • Page 17 Life Fitness Model 4500HR Treadmill DIAGNOSTIC TESTS (Continued) THE INCLINE DOWN t KEY IS USED FOR THE FOLLOWING TESTING INFORMATION: ⇒ ELEVATION TEST/ HOME SWITCH ⇒ SPEED MODE OPERATION ⇒ HEARTRATE MODE OPERATION POWER UP THE UNIT WHILE HOLDING DOWN THE INCLINE DOWN t KEY. THE DISPLAY CONSOLE WILL READ TEST MODE.
  • Page 18 Lifestride Model 4500HR Treadmill DIAGNOSTIC MODE ENTRY (Continued) SPEED MODE PRESS ANY SPEED KEY TO ENTER THE SPEED MODE. THE DISPLAY WILL PRESENT TWO NUMBERS. THE LEFT SIDE NUMBER REPRESENTS THE ACTUAL SPEED. THE RIGHT SIDE NUMBER REPRESENTS THE RELATIVE POWER APPLIED TO THE MOTOR. THE UNIT WILL SUPPLY A FIXED AMOUNT OF POWER TO THE DRIVE MOTOR IN THE SPEED MODE.

  • Page 19: How To

    Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE VENT COVER Tools Required: Phillips Screwdriver Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet. Step 2 Use a phillips screwdriver to remove the two SCREWS securing the sides of the VENT COVER to the MOTOR COVER.
  • Page 20 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE MOTOR COVER Tools Required: Phillips Screwdriver, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 21 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE DISPLAY CONSOLE Tools Required: Phillips Screwdriver Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet. Step 2 Remove the TRAY/HEART RATE kit. (See “How To...”).
  • Page 22 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE HANDLEBAR AND HANDRAILS Tools Required: Phillips Screwdriver, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 23 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE DECK AND STRIDING BELT Tools Required: Phillips Screwdriver, socket set, hex key wrench set IMPORTANT: THE DECK AND STRIDING BELT SHOULD ALWAYS BE REPLACED IN TANDEM. DO NOT REPLACE ONE WITHOUT THE OTHER.
  • Page 24 Life Fitness Model 4500HR Treadmill How To... REMOVE AND REPLACE THE FRONT ROLLER ASSEMBLY Tools Required: Phillips screwdriver, socket set, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 25 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE REAR ROLLER Tools Required Socket and ratchet set, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 26 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE HEATSINK CONTROL BOARD ASSEMBLY Tools Required: Phillips Screwdriver, socket and ratchet set, hex key wrench set WARNING: FAILURE TO OBSERVE SAFE PROCEDURES WHEN SERVICING THIS UNIT COULD RESULT IN INJURY FROM ELECTRICAL SHOCK Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 27 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE HEATSINK CONTROL BOARD ASSEMBLY ( Continued ) Step 6 Use a socket wrench to loosen and remove the two SCREWS securing the GROUNDING WIRES to the HEATSINK CONTROL BOARD ASSEMBLY.
  • Page 28 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE DISPLAY WIRE HARNESS Tools Required: Phillips Screwdriver, socket and ratchet set, hex key wrench set WARNING: FAILURE TO OBSERVE SAFE PROCEDURES WHEN SERVICING THIS UNIT COULD RESULT IN INJURY FROM ELECTRICAL SHOCK Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 29 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE LIFT ACTUATOR ASSEMBLY Tools Required: Phillips screwdriver, standard screwdriver, hex key wrench set WARNING: FAILURE TO OBSERVE SAFE PROCEDURES WHEN SERVICING THIS UNIT COULD RESULT IN INJURY FROM ELECTRICAL SHOCK Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 30 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE DRIVE MOTOR BELT Tools Required: Phillips screwdriver, socket and ratchet set, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 31 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE DRIVE MOTOR BELT ( Continued ) Step 5 Lift the FRONT ROLLER ASSEMBLY from the EXTRUSION BRACKETS and position the FRONT ROLLER within the STRIDING BELT to allow for removal of the DRIVE MOTOR BELT from the DRIVE MOTOR and FRONT ROLLER PULLEYS.
  • Page 32 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE DRIVE MOTOR Tools Required: Phillips screwdriver, socket and ratchet set, hex key wrench set Step 1 Turn the power OFF at the ON/OFF switch and then unplug the unit from the electrical outlet.
  • Page 33 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE DRIVE MOTOR ( Continued ) Step 7 Remove the two DRIVE MOTOR ASSEMBLY mounting SCREWS securing the ASSEMBLY to the MOTOR MOUNTING BRACKET by using a 1/4” hex wrench. Remove the DRIVE MOTOR ASSEMBLY from the unit.
  • Page 34 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE LIFESPRINGS Tools Required: Phillips screwdriver, socket and ratchet set, hex key wrench set Step 1 Turn the power OFF at the on/off switch and then unplug the unit from the electrical outlet.
  • Page 35 Life Fitness Model 4500HR Treadmill How To ... REMOVE AND REPLACE THE TRAY Tools Required: Phillips screwdriver Step 1 Turn the power OFF by unplugging the unit at the electrical outlet. Step 2 Remove the two SCREWS located on the underside of the TRAY which are securing the TRAY to the DISPLAY CONSOLE.
  • Page 36 Life Fitness Model 4500HR Treadmill How To... ADJUST AND TENSION THE STRIDING BELT Tools Required: Hex key wrench set, Phillips screwdriver CAUTION: DO NOT MOVE OR PLACE YOUR HANDS UNDER THE UNIT WHILE THE MACHINE IS PLUGGED INTO AN ELECTRICAL OUTLET.
  • Page 37 Life Fitness Model 4500HR Treadmill How To... ADJUST AND TENSION THE STRIDING BELT (Continued) Tools Required: Hex key wrench set, Phillips screwdriver Step 3 Repeat adjustments until the STRIDING BELT appears centered. Allow the machine to continue running for several minutes to observe if the tracking remains stabilized.
  • Page 38 Life Fitness Model 4500HR Treadmill NOTES:...
  • Page 39 Life Fitness Model 4500HR Treadmill WIRING BLOCK DIAGRAM...

  • Page 40: Vent Cover

    CAPACITOR, MOTOR 118E-00001-0056 CAPACITOR CAP (RED) 0017-00042-0859 CHOKE 111E-00001-0014 *CONTACT LIFE FITNESS AFTER MARKET SERVICES PRIOR TO ORDERING TO VERIFY SOFTWARE VERSIONS THE FOLLOWING ITEMS ARE NOT SHOWN: DECAL : EXTR TR-4500 OK40-01114-0001 DECAL : LOGO TR-4500 OK40-01022-0001 PARTS BAG ASSEMBLY...

  • Page 41: Parts Identification

    Life Fitness Model 4500HR Treadmill PARTS IDENTIFICATION...

  • Page 42: Communicating By Fax

    Life Fitness Model 4500HR Treadmill 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.
  • Page 43 AFTER MARKET 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. PART NUMBER DESCRIPTION QUANTITY PRODUCT TROUBLESHOOTING PRODUCT NAME: SERIAL NO.
  • Page 44 Life Fitness Model 4500HR Treadmill NOTES:...

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