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Life Fitness 4000 Service Manual

Life fitness treadmill service manual
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Model 4000 Treadmill
Customer Support Services
SERVICE MANUAL

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  Summary of Contents for Life Fitness 4000

  • Page 1 Model 4000 Treadmill Customer Support Services SERVICE MANUAL...
  • Page 2 © 1998 Life Fitness, a division of Brunswick Corporation. All rights reserved. All rights reserved. Life Fitness, Lifecycle, Lifepulse and Flexdeck are registered trademarks, and Heart Rate Zone Training, Lifespring and RELY ON IT are trademarks of Brunswick Corporation. Polar is a registered trademark of Polar.
  • Page 3 HOW TO USE THIS SERVICE MANUAL In the unlikely event that an operating problem may occur with your Life Fitness model 4000 treadmill, this Service Manual will instruct and guide you on the quickest, most efficient manner in which to approach the situation. This...
  • Page 4 FCC Warning - Possible Radio/Television Interference NOTE: This equipment has been tested and found to comply with the limits pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. Any changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment.
  • Page 5: Table Of Contents

    Life Fitness Model 4000 Treadmill TABLE OF CONTENTS INTRODUCTION (How to use this Service Manual) TABLE OF CONTENTS SECTION I THEORY OF OPERATION TROUBLESHOOTING GUIDES 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 6: Theory Of Operation

    Life Fitness Model 4000 Treadmill THEORY OF OPERATION The operational functions of the Life Fitness Model 4000 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 7: No Power

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE NO POWER Symptom: Malfunction No Power Probable Cause On/off switch Insufficient power source Line cord improperly seated in electrical outlet Damaged line cord Faulty Display Console Corrective Action Turn unit On. Plug treadmill into power source with proper electrical requirements.
  • Page 8: Noisy Treadmill

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE Malfunction Foreign objects may be stuck Rubbing sound from under the machine beneath machine Rubbing sound from Striding Belt not tracking properly Striding Belt Striding Belt is rubbing on extrusion or roller pulley...
  • Page 9: Striding Belt

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE STRIDING BELT Symptom: Malfunction Striding Belt will not move Striding Belt hesitates upon start up (or will not begin to turn on new machine) Maximum speed reduced Striding belt comes in contact with End Caps...
  • Page 10: Unit Resets Randomly

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE Malfunction Unit Resets Randomly Insufficient Power Source Damaged Line Cord Line Cord improperly seated in electrical outlet Low AC line voltage Loose connections Symptom: Probable Cause Plug Treadmill into power source with proper electrical requirements.
  • Page 11: Display Does Not Illuminate Or Respond To Input

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE DISPLAY DOES NOT ILLUMINATE OR RESPOND TO INPUT Symptom: Malfunction Display will not illuminate when machine is turned on. Probable Cause Insufficient power source. Loose connection at Display Console or Control Board. Faulty Control Board.
  • Page 12: Unit Will Not Elevate

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE Malfunction Unit will not elevate Unit jammed at top of elevation Symptom: Probable Cause Line Cord is crossed over lifting assembly Faulty Lift Actuator (limits) Defective Lift Actuator Faulty Control Board Faulty Home Switch...
  • Page 13: Error Display Messages

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE ERROR DISPLAY MESSAGES Symptom: Malfunction ERROR MESSAGES: START UP (Occurs when the Striding Belt, upon start up, will speed up at a high rate) RUNNING (Occurs at sudden change in Striding Belt Speed)
  • Page 14: Heart Rate Does Not Respond

    Life Fitness Model 4000 Treadmill TROUBLESHOOTING GUIDE Symptom: Malfunction Heart Rate cable not Heart Rate system does connected not respond Loose connection at Receiver Loose connection at Console User error User may have an unusual heart beat Faulty Transmitter and/or...
  • Page 15 Life Fitness Model 4000 Treadmill NOTES:...
  • Page 16: Diagnostic Tests

    Life Fitness Model 4000 Treadmill DIAGNOSTIC TESTS PURPOSE: This Section describes the test procedures for the Life Fitness 4000 Treadmill Display Console Board including the Heart Rate feature (operational only if equipped with the optional Heart Rate Kit Tray). SCOPE: Diagnostic procedures will test the Display Console Board as used in the final Treadmill assembly.
  • Page 17 CAL/HR LED lit: percentage of elevation and time 5th press SPEED LED lit: current limiter activation Press ENTER a fourth time and this will give you the software version of the treadmill. For example, the display reads 4.3EE1 translates to: SOFTWARE VERSION...
  • Page 18 Life Fitness Model 4000 Treadmill DIAGNOSTIC TESTS (Continued) The INCLINE key is used for the following testing information: ELEVATION TEST/ HOME SWITCH SPEED MODE OPERATION HEARTRATE MODE OPERATION (if equipped with optional heart rate kit) BLANKING ON/OFF Power up the unit while holding down the INCLINE entry into the test mode, the two columns of the program profile window will have one to two LED’s lit.
  • Page 19 The striding belt will begin to move at .5 mph. Grasp the handlebar and begin walking on the striding belt. Walk forward taking the smallest steps possible. This test will indicate the power draw on the treadmill. The average amount is 8 to 12 and will vary according to the technician’s weight. Excessively high numbers indicate a newer, non-broken in striding belt or a very old, worn belt.
  • Page 20: Vent Cover

    Life Fitness Model 4000 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. Monocolumn Motor Cover...
  • Page 21: Motor Cover

    Use a phillips screwdriver to remove the SCREW securing the RETAINING PLATE and FIBERBOARD WEDGE in place on the MONOCOLUMN. Step 4 Remove the four SCREWS securing the MOTOR COVER in place against the Treadmill FRAME. Lift the MOTOR COVER from the machine. Step 5 Place the new MOTOR COVER in position and reverse Steps 1 through 4 to return all parts to their proper locations.
  • Page 22: Display Console

    Life Fitness Model 4000 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, if equipped with the optional HEART RATE kit. (See “How To...”).
  • Page 23: Handlebar And Handrails

    Step 4 Loosen and remove the 2” (top) and the 2-1/2” (bottom) SCREWS securing the base of each of the two VERTICAL POSTS to the FOOT BRACKETS located on either side of the treadmill. Step 5 Lift the entire HANDLEBAR/HANDRAIL ASSEMBLY away from the machine and set it down on the floor. Remove the SCREW securing each of the two VERTICAL POSTS to the foam padded HANDLEBARS and slide the POSTS from the HANDLEBARS.
  • Page 24: Deck And Striding Belt

    Life Fitness Model 4000 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 25: How To...adjust And Tension The Striding Belt

    Life Fitness Model 4000 Treadmill How To ... ADJUST AND TENSION THE STRIDING BELT Tools Required: Hex key wrench set, phillips screwdriver A. REPLACING THE STRIDING BELT WITH A NEW STRIDING BELT CAUTION: WHENEVER REMOVING OR REINSTALLING AN EXISTING STRIDING BELT, DO NOT REMOVE OR LOOSEN THE FRONT ROLLER.
  • Page 26 CAUTION: DO NOT MOVE OR PLACE YOUR HANDS UNDER THE UNIT WHILE THE MACHINE IS PLUGGED INTO AN ELECTRICAL OUTLET. It is EXTREMELY important that the treadmill be correctly leveled prior to any tracking adjustments. An unstable unit may cause Striding Belt misalignment.
  • Page 27: How To...adjust And Tension The Striding Belt

    Step 4. if it does not slip, the tension is correct. Step 4 Stop the treadmill and alternately turn the STRIDING BELT TENSIONING BOLTS 1/4 turn clock-wise to tension, NOT exceeding one full turn. (See Tracking (Centering) an Existing or New Striding Belt on previous page.
  • Page 28: Front Roller Assembly

    Life Fitness Model 4000 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 29 Life Fitness Model 4000 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 30: Heatsink Control Board Assembly

    Life Fitness Model 4000 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 31: Heatsink Control Board Assembly

    How To ... REMOVE AND REPLACE THE HEATSINK CONTROL BOARD ASSEMBLY Step 6 Use a socket wrench to loosen and remove the two SCREWS securing the GROUNDING WIRES to the HEATSINK CONTROL BOARD ASSEMBLY. Step 7 Lift off the PROTECTIVE COVER from the top of the CAPACITOR. Remove the NEGATIVE WIRE CONNECTORS leading from the DRIVE MOTOR ASSEMBLY to the CAPACITOR.
  • Page 32: Display Wire Harness

    Life Fitness Model 4000 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 33: Lift Actuator Assembly

    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. Step 2 Remove the VENT COVER.
  • Page 34: Drive Motor Belt

    Life Fitness Model 4000 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 35: Drive Motor Belt

    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 36: Drive Motor Assembly

    Life Fitness Model 4000 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 37: Drive Motor Assembly

    Life Fitness Model 4000 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 38: Lifesprings

    Life Fitness Model 4000 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 39: Tray ( Optional Heart Rate Kit )

    Life Fitness Model 4000 Treadmill How To ... REMOVE AND REPLACE THE TRAY ( Optional Heart Rate Kit ) 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 40 Life Fitness Model 4000 Treadmill NOTES:...
  • Page 41: Wiring Diagram

    Life Fitness Model 4000 Treadmill WIRING DIAGRAM Life Fitness Model 4000 Treadmill...
  • Page 42: Parts Identification

    PARTS IDENTIFICATION SN # 558000 - UP Console Assembly AK40-00057-0001(R) Eng/Met AK40-00057-0004(R) Frn/Met Handlebar w/Grips OK40-01092-0001 Stop Key/Clip AK40-00035-0000 Handrail Tube OK40-01006-0001 Leg Leveler 0017-00009-0796 Overlay Bezel AK40-00058-0001 Eng/Eng AK40-00058-0004 Frn/Met Mono-Column OK40-01093-0001 Motor Shroud AK40-00037-0002 Wheel OK40-01021-0000...
  • Page 43 Life Fitness Model 4000 Treadmill PARTS IDENTIFICATION SN # 558000 - UP Tray w/Heart Rate(optional) GK40-00002-0006 Tray(optional) OK40-01095-0001 Telemetry Receiver SK40-00045-0001 Vent Cover ON/OFF Switch AK40-00039-0001 AK40-00052-0000 Removable Safety Switch 0017-00032-0191 End Cap(RT) OK40-01086-0007 Handrail Mount OK40-01034-0001 Display Cable AK36-00017-0000...
  • Page 44 Life Fitness Model 4000 Treadmill PARTS IDENTIFICATION SN # 558000 - UP...
  • Page 45: Communicating By Fax

    Life Fitness Model 4000 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 46 PARTS ORDER PRODUCT TROUBLESHOOTING NAME: PHONE: METHOD OF SHIPMENT: PARTS ORDER FORM ITEM NO. PART NUMBER PRODUCT TROUBLESHOOTING PRODUCT NAME: DETAILED DESCRIPTION OF PROBLEM: PRODUCT NAME: DETAILED DESCRIPTION OF PROBLEM: TIME RECEIVED: 10601 W. Belmont Ave., Franklin Park IL 60131 PHONE (800) 351-3737 Toll Free or (847) 451-0036 CUSTOMER SUPPORT SERVICES ( IF BOTH PLEASE INDICATE )
  • Page 47 Life Fitness Model 4000 Treadmill NOTES:...