Life Fitness 4000 User Manual
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
TM
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.
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
INTRODUCTION (How to use this Service Manual)
TABLE OF CONTENTS
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
How To...ADJUST AND TENSION THE STRIDING BELT ..........................................................6-8
VENT COVER.................................................................................................................. 1
MOTOR COVER .............................................................................................................. 2
DISPLAY CONSOLE ....................................................................................................... 3
HANDLEBAR AND HANDRAILS ...................................................................................... 4
DECK AND STRIDING BELT........................................................................................... 5
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
Insufficient power source Plug treadmill into power source with proper
Line cord improperly seated in
electrical outlet
Damaged line cord Replace line cord.
Faulty Display Console See “Display Console “ symptom.
Turn unit On.
electrical requirements.
(See Operation Manual)
Inspect power connection at outlet.
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
Malfunction Probable Cause Corrective Action
Symptom: NOISY TREADMILL
Rubbing sound from
beneath machine
Rubbing sound from
Striding Belt
Popping sound
Squeaking noise
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 Check Drive Motor Pulley to insure Pulley is
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.
aligned with Front Roller Pulley. Tighten the
Set Screws to secure the Pulley into place.
“Groaning” sound heard
from front of machine
Loud “Groaning” sound
heard from front of
machine while elevating
Drive Motor Belt overtensioned
Weak Drive Motor/Drive Motor
Software
Faulty Drive Motor Replace Drive Motor
Faulty Lift Actuator Perform “Lift Test”. (See Diagnostics).
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 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 Probable Cause
Striding Belt will not move
Striding Belt hesitates
upon start up (or will not
begin to turn on new
machine)
Maximum speed reduced
Corrective Action
Insufficient power source
Faulty Control Board
High amount of friction
between Deck and Striding
Belt.
Striding Belt, Deck Malfunction
• Deck laminate is worn
through
• Belt worn
Line Voltage too low Plug the Treadmill into a power source with the
Striding Belt slips Adjust Striding Belt Tension (See “How To...”)
Drive Motor Belt slipping See “How To...Remove and Replace the Drive
Plug treadmill into power source with proper
electrical requirements. (See Operation
Manual)
Replace Control Board
Start unit with no one on it at 3.5 mph and 5%
or greater incline. Step on to the Belt while it is
moving and walk for 4 to 5 minutes.
Replace Striding Belt and Deck
proper electrical requirements.
Motor Belt” for proper Drive Motor Belt
tensioning instructions.
Striding belt comes in
contact with End Caps
Unit is not level Adjust rear leveling legs (See Operation
Manual)
Striding Belt needs to be retensioned
Missing rubber spacer Replace rubber spacer between Frame and
End Cap(s) distorted Replace End Cap(s)
Striding Belt stretched or too
long
Adjust Striding Belt Tension (See “How To...”)
End Cap
Replace Deck and Striding Belt
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
Malfunction Probable Cause Corrective Action
Symptom: UNIT RESETS RANDOMLY
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
electrical outlet
Low AC line voltage Too many items tied into AC line. Use a
Loose connections Check and secure all connectors
Secure connection at electrical outlet.
different circuit line outlet.
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
when machine is turned on.
Insufficient power source. Plug Treadmill into power source with proper
electrical requirements. (See Operation
Manual)
Loose connection at Display
Console or Control Board.
Faulty Control Board. With a volt meter check cable voltage at P1
Faulty Display Console. Replace Display Console.
Secure connections at Display Console and
Control Board.
(Console cable) for 8v DC. (pin #2 positive )
(pin #8 negative).
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
Malfunction Probable Cause Corrective Action
Symptom: UNIT WILL NOT ELEVATE
Unit will not elevate
Unit jammed at top of
elevation
Line Cord is crossed over lifting
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
Check position of Line Cord placement.
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)
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
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.
OVER SPEED
(Striding Belt moving faster
than commanded)
8
Faulty ON/OFF switch
Damaged Control Board
Faulty Control Board
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
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
connected
Loose connection at Receiver
Loose connection at Console
User error
User may have an unusual
heart beat
Faulty Transmitter and/or
Receiver (Heart Rate kit)
Faulty Display Console
Outside noise (Cross talk)
Check all electrical connections.
Secure connection at Receiver
Secure connection at Console and Handlebar.
Check Heart Rate kit operating instructions
Have different people try Transmitter (chest) strap.
Replace Transmitter and/or Receiver (Heart Rate kit).
Replace Display Console.
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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