Model 4000 Treadmill
Customer Support Services
SERVICE MANUAL
© 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. Any use of these trademarks, without the express written consent of Life Fitness or the corresponding companies is forbidden.
M051-00K40-A030
10-98
Life Fitness Model 4000 Treadmill
INTRODUCTION
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 Service Manual has been separated into a total of Four Sections for quick reference:
o INTRODUCTION
o TABLE OF CONTENTS
Section I
o THEORY OF OPERATION
o TROUBLESHOOTING GUIDES
Section II
o DIAGNOSTIC TESTS
Section III
o MODEL 4000 "How To..." GUIDES
Section IV
o WIRING DIAGRAMS
o PARTS IDENTIFICATION o COMMUNICATING BY FAX
If an operating problem should arise, turn to the TROUBLESHOOTING GUIDES and attempt to isolate what is causing the malfunction. The GUIDES are listed by symptoms and follow with suggestions as to the most probable cause of the problem.
Once you have pinpointed the source of the problem, turn to the appropriate "How To..." section and review the proper procedures for removing, replacing or adjusting a part. The "How To..." sections are organized by replaceable part (or assembly) name and each page lists the “Tools Required“ to complete that specific function. Refer to Section IV to identify the proper name and number of the part you will now need to order to repair your machine. A form to order by FAX has also been included in Section IV for your convenience.
To order a part, call Life Fitness Customer Support 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.The Treadmill model type (4000)
2.The serial number ( Located on the front crossbar between the two wheels)
Serial Number:
3.The symptom of the problem you are experiencing
4.The part name and number you need to order
When you receive your order, review the appropriate "How To..." section and follow the step by step procedures designed to help you install the part quickly and correctly.
If you have any questions or comments please phone, mail, or fax us at one of the numbers listed below.
T
CUSTOMER SUPPORT SERVICES
10601 Belmont Avenue, Franklin Park, IL 60131 Phone ( 800 ) 351-3737 Toll Free or (847) 451-0036 FAX (800) 216-8893 Toll Free or (847) 288-3702
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. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that the interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, you are encouraged to try to correct the interference by one or more of the following measures:
•Reorient or relocate the receiving antenna.
•Increase the space between the equipment and the receiver.
•Connect the equipment to an outlet on a different circuit than that to which the receiver is connected.
•Consult an exercise equipment dealer or an experienced radio/TV technician for help.
You are cautioned that any changes or modifications to this equipment could void your product warranty.
Life Fitness Model 4000 Treadmill |
|
TABLE OF CONTENTS |
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INTRODUCTION (How to use this Service Manual) |
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TABLE OF CONTENTS |
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SECTION I |
PAGE |
THEORY OF OPERATION |
1 |
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.............................................................................................. |
7 |
ERROR DISPLAY MESSAGES ....................................................................................... |
8 |
HEART RATE DOES NOT RESPOND ............................................................................ |
9 |
( If Equipped with Optional Heart Rate Kit Tray ) |
|
SECTION II |
|
DIAGNOSTIC TESTS................................................................................................................... |
1-4 |
SECTION III |
|
How To...REMOVE AND REPLACE THE |
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VENT COVER.................................................................................................................. |
1 |
MOTOR COVER.............................................................................................................. |
2 |
DISPLAY CONSOLE ....................................................................................................... |
3 |
HANDLEBAR AND HANDRAILS...................................................................................... |
4 |
DECK AND STRIDING BELT........................................................................................... |
5 |
How To...ADJUST AND TENSION THE STRIDING BELT .......................................................... |
6-8 |
FRONT ROLLER ASSEMBLY ......................................................................................... |
9 |
REAR ROLLER ASSEMBLY............................................................................................ |
10 |
HEATSINK CONTROL BOARD ASSEMBLY ................................................................... |
11,12 |
DISPLAY WIRE HARNESS ............................................................................................. |
13 |
LIFT ACTUATOR ASSEMBLY ......................................................................................... |
14 |
DRIVE MOTOR BELT...................................................................................................... |
15,16 |
DRIVE MOTOR ASSEMBLY............................................................................................ |
17,18 |
LIFESPRINGS ................................................................................................................. |
19 |
TRAY ( Optional Heart Rate Kit )...................................................................................... |
20 |
SECTION IV |
|
WIRING DIAGRAM ...................................................................................................................... |
1 |
PARTS IDENTIFICATION ............................................................................................................ |
2-4 |
COMMUNICATING BY FAX ......................................................................................................... |
5,6 |
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. The display console then determines the appropriate action to be taken and passes low level signals to the control board. The control board converts low level signals to high level signals and forwards them to the drive motor and the lift actuator to execute the requested command. All of the “Intelligence” within the Treadmill is located in the display console.
Control Board
The control board provides power for the Treadmill, acts as an interface between the display console, drive motor and lift actuator, and also acts as an additional interface between the speed sensing and lift limit switches. The drive motor trigger, lift actuator time and direction, and safety power relay signals are received from the display console and routed through the control board to execute a command. Speed sensing and lift limit signals are also passed through the control board to the display console.
Display Console
The display console is the user interface that allows selection from the various programs and options offered by the Treadmill. The display console provides all of the “Intelligence” within the Treadmill, controls the information displays, and monitors the keypad and safety switches. It determines the drive motor and lift actuator actions to suit the chosen Life Fitness aerobic training program and it also accommodates the optional heart rate receiver.
Drive Motor
The drive motor is the component responsible for moving the striding belt. The speed sensor, located on the drive motor, sends pulses through the control board to the display console which converts them to the striding belt speed. The display console adjusts the power to the drive motor to maintain a constant speed to the striding belt resulting in a more comfortable “feel”.
Lift Actuator
The lift actuator is the component responsible for raising and lowering the incline level of the Treadmill. The display console, through the control board, will raise and lower the lift actuator for the appropriate amount of time and incline required by a specific command. The “Home” lift limit switch signals the display console when the lift actuator is at 0% incline. The lift actuator also has its own internal built-in limit switches.
1
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: NO POWER
Malfunction |
Probable Cause |
Corrective Action |
No Power |
On/off switch |
Turn unit On. |
|
Insufficient power source |
Plug treadmill into power source with proper |
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electrical requirements. |
|
|
(See Operation Manual) |
|
Line cord improperly seated in |
Inspect power connection at outlet. |
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electrical outlet |
|
|
Damaged line cord |
Replace line cord. |
|
Faulty Display Console |
See “Display Console “ symptom. |
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
2
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: NOISY TREADMILL
Malfunction |
Probable Cause |
Corrective Action |
Rubbing sound from beneath machine
Rubbing sound from Striding Belt
Popping sound
Squeaking noise
“Groaning” sound heard from front of machine
Loud “Groaning” sound heard from front of machine while elevating
Foreign objects may be stuck under the machine
Striding Belt not tracking properly
Striding Belt is rubbing on extrusion or roller pulley
Striding Belt is rubbing on belt guide
Insufficient break-in period
Wax accumulation on rear roller
Lifesprings may be out of alignment
Drive Motor Belt may be worn or damaged
Drive Motor Pulley shifted
Drive Motor Belt overtensioned
Weak Drive Motor/Drive Motor
Software
Faulty Drive Motor
Faulty Lift Actuator
Inspect underneath Belt and Machine. Remove any debris or accumulation.
Adjust Striding Belt tracking. See “How To...Adjust and Tension the Striding Belt”
Center Striding Belt. See “How To...Adjust and Tension the Striding Belt”
Center Striding Belt. See “How To...Adjust and Tension the Striding Belt”
A new Deck and Striding Belt will require a break-in period of approx. 20 hours.
Run machine at 4 to 5 MPH to distribute wax onto Striding Belt.
Reposition the Lifesprings.
Replace Drive Motor Belt.
Check Drive Motor Pulley to insure Pulley is aligned with Front Roller Pulley. Tighten the Set Screws to secure the Pulley into place.
Slacken Drive Belt tension (See “How To...Remove and Replace the Drive Motor Belt”)
Check Drive Motor Flywheel and Software for compatibility (See Diagnostic Software Version.
Replace Drive Motor
Perform “Lift Test”. (See Diagnostics). Replace faulty Lift Actuator.
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
3
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: STRIDING BELT
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
|
Probable Cause |
Corrective Action |
Insufficient power source |
Plug treadmill into power source with proper |
|
|
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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% |
|
between Deck and Striding |
or greater incline. Step on to the Belt while it is |
|
Belt. |
moving and walk for 4 to 5 minutes. |
|
Striding Belt, Deck Malfunction |
Replace Striding Belt and Deck |
|
∙ |
Deck laminate is worn |
|
|
through |
|
∙ |
Belt worn |
|
Line Voltage too low |
Plug the Treadmill into a power source with the |
|
|
|
proper electrical requirements. |
Striding Belt slips |
Adjust Striding Belt Tension (See “How To...”) |
|
Drive Motor Belt slipping |
See “How To...Remove and Replace the Drive |
|
|
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Motor Belt” for proper Drive Motor Belt |
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tensioning instructions. |
Unit is not level |
Adjust rear leveling legs (See Operation |
|
|
|
Manual) |
Striding Belt needs to be re- |
Adjust Striding Belt Tension (See “How To...”) |
|
tensioned |
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|
Missing rubber spacer |
Replace rubber spacer between Frame and |
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|
|
End Cap |
End Cap(s) distorted |
Replace End Cap(s) |
|
Striding Belt stretched or too |
Replace Deck and Striding Belt |
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long |
|
|
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
4
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
|
Symptom: UNIT RESETS RANDOMLY |
|
|
|
|
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. |
|
Line Cord improperly seated in |
Secure connection at electrical outlet. |
|
electrical outlet |
|
|
Low AC line voltage |
Too many items tied into AC line. Use a |
|
|
different circuit line outlet. |
|
Loose connections |
Check and secure all connectors |
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
5
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: DISPLAY DOES NOT ILLUMINATE OR RESPOND TO INPUT
Malfunction |
Probable Cause |
Corrective Action |
Display will not illuminate |
Insufficient power source. |
Plug Treadmill into power source with proper |
when machine is turned on. |
|
electrical requirements. (See Operation |
|
|
Manual) |
|
Loose connection at Display |
Secure connections at Display Console and |
|
Console or Control Board. |
Control Board. |
|
Faulty Control Board. |
With a volt meter check cable voltage at P1 |
|
|
(Console cable) for 8v DC. (pin #2 positive ) |
|
|
(pin #8 negative). |
|
Faulty Display Console. |
Replace Display Console. |
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
6
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: UNIT WILL NOT ELEVATE
Malfunction |
Probable Cause |
Corrective Action |
Unit will not elevate
Unit jammed at top of elevation
Line Cord is crossed over lifting |
Check position of Line Cord placement. |
assembly |
|
Faulty Lift Actuator (limits) |
Perform Lift Test (See Diagnostics). |
Defective Lift Actuator |
Replace Lift Actuator |
Faulty Control Board |
Replace Control Board |
Faulty Home Switch |
Perform Lift Home Switch Test |
Defective Home Switch |
Replace Home Switch |
Faulty Control Board |
Replace Control Board |
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
7
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: ERROR DISPLAY MESSAGES
Malfunction |
Probable Cause |
Corrective Action |
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)
BELT MOVING
(Occurs at interruption in power or when machine is just plugged in)
OVER SPEED
(Striding Belt moving faster than commanded)
Bad connection to Opto Speed Sensor
Misaligned or damaged Opto Speed Sensor
Moving Striding Belt was suddenly stopped
Bad connection to Opto Speed Sensor
Misaligned or damaged Opto Speed Sensor
Spike or interruption in power
Bad connection or damaged Line Cord
Faulty ON/OFF switch
Damaged Control Board
Faulty Control Board
Check all electrical connections.
Adjust or replace Opto Speed Sensor.
Reset machine by turning power OFF and ON at ON/OFF switch.
Check all electrical connections.
Adjust or replace Opto Speed Sensor.
Reset machine by turning power OFF and ON at ON/OFF switch.
Check all electrical connections or replace Line Cord.
Replace switch.
Replace Control Board.
Replace Control Board
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
8
Life Fitness Model 4000 Treadmill
TROUBLESHOOTING GUIDE
Symptom: OPTIONAL HEARTRATE KIT DOES NOT RESPOND
Malfunction |
Probable Cause |
Corrective Action |
Heart Rate system does not respond
Heart Rate cable not |
Check all electrical connections. |
connected |
|
Loose connection at Receiver |
Secure connection at Receiver |
Loose connection at Console |
Secure connection at Console and Handlebar. |
User error |
Check Heart Rate kit operating instructions |
User may have an unusual |
Have different people try Transmitter (chest) strap. |
heart beat |
|
Faulty Transmitter and/or |
Replace Transmitter and/or Receiver (Heart Rate kit). |
Receiver (Heart Rate kit) |
|
Faulty Display Console |
Replace Display Console. |
Outside noise (Cross talk) |
Move unit to another location. |
For Assistance:
Call Life Fitness Customer Support Services 1-847-451-0036 or 1-800-351-3737
9
Life Fitness Model 4000 Treadmill
NOTES:
10
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