Life Fitness 4000 Service 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
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
M
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
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
No Power
Probable Cause
Corrective Action
On/off switch
Turn unit On.
Insufficient power source
Plug treadmill into power source with proper
electrical requirements.
(See Operation Manual)
Line cord improperly seated in
electrical outlet
Inspect power connection at 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
Foreign objects may be stuck
under the machine
Inspect underneath Belt and Machine. Remove
any debris or accumulation.
Rubbing sound from
Striding Belt
Striding Belt not tracking
properly
Adjust Striding Belt tracking. See “How
To...Adjust and Tension the Striding Belt”
Striding Belt is rubbing on
extrusion or roller pulley
Center Striding Belt. See “How To...Adjust and
Tension the Striding Belt”
Striding Belt is rubbing on belt
guide
Center Striding Belt. See “How To...Adjust and
Tension the Striding Belt”
Insufficient break-in period
A new Deck and Striding Belt will require a
break-in period of approx. 20 hours.
Wax accumulation on rear
roller
Run machine at 4 to 5 MPH to distribute wax
onto Striding Belt.
Lifesprings may be out of
alignment
Reposition the Lifesprings.
Drive Motor Belt may be worn
or damaged
Replace Drive Motor Belt.
Drive Motor Pulley shifted
Check Drive Motor Pulley to insure Pulley is
aligned with Front Roller Pulley. Tighten the
Set Screws to secure the Pulley into place.
Drive Motor Belt overtensioned
Slacken Drive Belt tension (See “How
To...Remove and Replace the Drive Motor
Belt”)
Weak Drive Motor/Drive Motor
Software
Check Drive Motor Flywheel and Software for
compatibility (See Diagnostic Software
Version.
Faulty Drive Motor
Replace Drive Motor
Faulty Lift Actuator
Perform “Lift Test”. (See Diagnostics).
Replace faulty Lift Actuator.
Popping sound
Squeaking noise
“Groaning” sound heard
from front of machine
Loud “Groaning” sound
heard from front of
machine while elevating
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
Corrective Action
Insufficient power source
Plug treadmill into power source with proper
electrical requirements. (See Operation
Manual)
Faulty Control Board
Replace Control Board
Striding Belt hesitates
upon start up (or will not
begin to turn on new
machine)
High amount of friction
between Deck and Striding
Belt.
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.
Maximum speed reduced
Striding Belt, Deck Malfunction
• Deck laminate is worn
through
• Belt worn
Replace Striding Belt and Deck
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
Motor Belt” for proper Drive Motor Belt
tensioning instructions.
Unit is not level
Adjust rear leveling legs (See Operation
Manual)
Striding Belt needs to be retensioned
Adjust Striding Belt Tension (See “How To...”)
Missing rubber spacer
Replace rubber spacer between Frame and
End Cap
End Cap(s) distorted
Replace End Cap(s)
Striding Belt stretched or too
long
Replace Deck and Striding Belt
Striding Belt will not move
Striding belt comes in
contact with End Caps
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
Unit Resets Randomly
Probable Cause
Corrective Action
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
Secure connection at 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
Display will not illuminate
when machine is turned on.
Probable Cause
Corrective Action
Insufficient power source.
Plug Treadmill into power source with proper
electrical requirements. (See Operation
Manual)
Loose connection at Display
Console or Control Board.
Secure connections at Display Console and
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
Unit will not elevate
Unit jammed at top of
elevation
Probable Cause
Corrective Action
Line Cord is crossed over lifting
assembly
Check position of Line Cord placement.
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
Check all electrical connections.
Misaligned or damaged Opto
Speed Sensor
Adjust or replace Opto Speed Sensor.
Moving Striding Belt was
suddenly stopped
Reset machine by turning power OFF and ON at
ON/OFF switch.
Bad connection to Opto Speed
Sensor
Check all electrical connections.
Misaligned or damaged Opto
Speed Sensor
Adjust or replace Opto Speed Sensor.
Spike or interruption in power
Reset machine by turning power OFF and ON at
ON/OFF switch.
Bad connection or damaged
Line Cord
Check all electrical connections or replace Line Cord.
Faulty ON/OFF switch
Replace switch.
Damaged Control Board
Replace Control Board.
Faulty 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
Heart Rate system does
not respond
Probable Cause
Corrective Action
Heart Rate cable not
connected
Check all electrical connections.
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
heart beat
Have different people try Transmitter (chest) strap.
Faulty Transmitter and/or
Receiver (Heart Rate kit)
Replace Transmitter and/or 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
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. These
procedures will insure proper functioning of the Console LED’s, Keys and Displays as well as identify the Console
version.
PROCEDURE:
Begin with the Treadmill turned OFF. Hold the designated key during power up to enter into the chosen Diagnostic
Menu.
Continued
1
Life Fitness Model 4000 Treadmill
DIAGNOSTIC TESTS (Continued )
The SPEED τ 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.
Power up the unit while holding the SPEED τ key. All LED’s on the display console will light. Press ENTER once
and the console will begin to scroll through lighting LED’s individually.
Press ENTER a second time and this will bring you to the keypad test. By pressing each of the six keys, a pattern
of LED’s will light. This verifies that each of the keys is responding as intended.
Press ENTER a third time and the word “STATS” will appear in the display readout. Pressing the SPEED τ key will
scroll you through the individual statistics. (To scroll back through the statistics, press the SPEED σ key).
1st press
2nd press
3rd press
4th press
5th press
DISTANCE LED lit: miles ( in hundreds)
TIME LED lit: motor on time (in seconds)
INCLINE LED lit: lift motor run time (1/8 of a second)
CAL/HR LED lit: percentage of elevation and time
(percentage of elevation usage)
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:
4.3
E
E
1
SOFTWARE VERSION
ENGLISH MEASUREMENT (MILES)
ENGLISH LANGUAGE
120V
Press ENTER a fifth time and “UNITS” appears in the display readout. Pressing the SPEED σ key will change the
unit of measure from english to metric.
Press ENTER a sixth time and “LANG” appears in the display readout. Pressing the SPEED σ key enables you to
change from english to a foreign language.
You can go back to the start at any time in this test mode by pressing the CLEAR/PAUSE key.
Continued
2
Life Fitness Model 4000 Treadmill
DIAGNOSTIC TESTS (Continued)
The INCLINE τ 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 τ key. The display console will read TEST MODE. Upon initial
entry into the test mode, the two columns of the program profile window will have one to two LED’s lit.
The first three LED’s (from the top) of the left column are related to jumpers which are not applicable to any of the
test modes.
The fourth LED from the top indicates the condition of the OPTO SPEED SENSOR. When lit, the OPTO SPEED
SENSOR is reading through a slot in the chopper wheel that is mounted on the motor. When the LED is off, the
OPTO SPEED SENSOR is being blocked by a slot on the chopper wheel. Normal function of the LED is that it
flashes on and off as the drive motor turns during operation.
The fifth LED from the top will inform you if the unit is a 120v or a 220v unit. When the LED is off, the unit is 110v.
When the LED is on, the unit is 220v.
The sixth LED from the top indicates the elevation (HOME SWITCH). When the LED is off, the HOME SWITCH is
engaged and the unit is at zero elevation. When the LED is lit, the HOME SWITCH is disengaged and the unit is
at a non-zero elevation.
The left, bottom LED is the EMERGENCY STOP SWITCH condition. When this LED is lit, the EMERGENCY
STOP SWITCH is engaged and the unit operates. When the LED is off, the EMERGENCY STOP SWITCH is
disengaged and the unit will not run.
The right, bottom LED informs you if the BLANK STATE is set to the ON or OFF position.
Continued
3
Lifestride Model 4000 Treadmill
DIAGNOSTIC MODE ENTRY (Continued)
TO TEST THE ELEVATION:
Press the INCLINE σ key to elevate the treadmill. Press the INCLINE τ key to lower the unit. A beeping will occur
while the unit is being lowered and the home switch is activated.
To completely lower the elevation, set the incline to 0%. The unit will continue to lower its elevation until the home
switch or internal limit switch is engaged.
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.
HEART RATE MODE (if equipped with optional heart rate kit)
The user must have the heart rate transmitter and receiver attached in their proper positions for the heart rate to
display. By pressing ENTER, the users heart rate will appear on the display’s readout.
INCLINE σ KEY
Power up the unit while holding down the INCLINE σ key.
NOTE: Do not stand on the striding belt during power up.
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.
BLANKING MODE
The display console is factory set to stay lit when the treadmill is not in use.
To turn the display console ON or OFF, power up the unit while holding down the CLEAR key. Repeating this
action will act as a toggle between ON and OFF. When the BLANKING is in the OFF mode, the display will read
“DISPLAY OFF” and the display will automatically act as a screen saver and shut off after 4 minutes of non-use.
4
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
Vent Cover
Screws
Step 2
Use a phillips screwdriver to remove the two SCREWS securing the sides of the VENT COVER to the MOTOR
COVER.
Step 3
Grasp the VENT COVER in the center and pull away from the MOTOR COVER to disengage the two snap down
CLIPS located on the inside, center of the VENT COVER.
Step 4
Position the new VENT COVER into place and reverse steps 1 through 3 to return all parts to their proper
locations.
1
Life Fitness Model 4000 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.
Step 2
Remove the VENT COVER (See “How To...”).
Step 3
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.
2
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...”).
Step 3
Use a phillips screwdriver to remove the two SCREWS securing the extended neck of the DISPLAY CONSOLE to
the front and back of the MONOCOLUMN.
Step 4
Carefully lift the worn DISPLAY CONSOLE up from the MONOCOLUMN and unplug the 12-PIN CONNECTOR of
the WIRE HARNESS from the back of the DISPLAY CONSOLE.
Step 5
Plug the 12-PIN CONNECTOR of the WIRE HARNESS protruding from the top of the MONOCOLUMN into the
corresponding PC BOARD CONNECTOR located on the back of the new DISPLAY CONSOLE. Once connected,
feed the excess CABLE of the WIRE HARNESS back into the top of the MONOCOLUMN and lower the DISPLAY
CONSOLE into position on the MONOCOLUMN. Secure the extended neck of the DISPLAY CONSOLE to the
front and back of the MONOCOLUMN with the two SCREWS.
Step 6
Plug the unit into an electrical outlet and turn the power ON at the ON/OFF switch to resume operation.
3
Life Fitness Model 4000 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.
Step 2
Remove the DISPLAY CONSOLE. (See “How To...”).
Step 3
Remove the two HEX KEY SCREWS securing the center of the foam padded HANDLEBAR to the top of the
MONOCOLUMN.
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.
Step 6
Replace the VERTICAL POST(S) or HANDLEBAR as desired and reverse Steps 1 through 5 to return all parts to
their proper positions.
4
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.
Step 1
Turn the power OFF at the ON/OFF switch and then unplug
the unit from the electrical outlet.
Step 2
Remove the MOTOR COVER. (See “How To...”).
Step 3
Use a phillips screwdriver to remove the three SCREWS
securing each of the END CAPS to the Treadmill FRAME.
Remove the END CAPS and set aside.
Step 4
Remove the REAR ROLLER from the machine.
(See “How To...”).
Step 5
Remove the FRONT ROLLER ASSEMBLY. (See “How To...”).
Step 6
Use a hex key wrench to loosen and remove the four SCREWS securing the top of the DECK to the FRAME
ASSEMBLY.
Step 7
Remove the worn DECK and STRIDING BELT from the FRAME ASSEMBLY.
Step 8
Position a new DECK and STRIDING BELT in place and reverse Steps 1 through 6 to return all parts to their
proper locations. Refer to “How to...ADJUST AND TENSION THE STRIDING BELT” for proper BELT tensioning
instructions
NOTE: DO NOT OVERTIGHTEN THE TENSIONING BOLTS TO AVOID DAMAGE TO
THE STRIDING BELT AND THE ROLLER BEARINGS.
5
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.
Step 1
After installing the new STRIDING BELT, but prior to tensioning, place two pieces of tape exactly 38.5 inches
(97.79 cm) apart on both the right and left edges of the STRIDING BELT.
Tape (4 Places)
38.5 Inches
Step 2
Alternately tighten the two TENSIONING BOLTS 1/4 turn clockwise each until the distance between the tapes is
38.75 inches (98.425 cm) which is the equivalent of .65% stretch.
Step 3
Adjust TRACKING.
6
Life Fitness Model 4000 Treadmill
How To... ADJUST AND TENSION THE STRIDING BELT (Continued)
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.
It is EXTREMELY important that the treadmill be correctly leveled prior to any tracking adjustments.
An unstable unit may cause Striding Belt misalignment.
Tracking (Centering) an Existing or New Striding Belt
Step 1
Locate the two belt TENSIONING BOLTS on each side of the REAR ROLLER MOUNTING BRACKETS. The
TENSIONING BOLTS are accessible from the holes provided in the ENDCAPS.
Step 2
Enter the Manual program and set the belt speed to run at 4.0 mph.
NOTE: EACH ADJUSTMENT MADE TO ONE SIDE OF THE REAR ROLLER MUST BE MET WITH AN
EQUAL AND OPPOSITE ADJUSTMENT TO THE OTHER SIDE OF THE REAR ROLLER TO
MAINTAIN AN IDEAL BELT TENSION AT THE PIVOT POINT.
CAUTION: DO NOT OVER TIGHTEN THE TENSIONING BOLTS WHILE MAKING BELT ADJUSTMENTS.
OVER TIGHTENING OF BOLTS MAY OVER STRETCH AND DAMAGE THE STRIDING BELT AS WELL AS
PLACE AN UNNECESSARY LOAD ON THE REAR ROLLER BEARINGS.
If the STRIDING BELT has moved to the right,
turn the right TENSION BOLT 1/4 turn clock-wise
and the left TENSION BOLT 1/4 turn counterclockwise to start the STRIDING BELT tracking
back to the center of the REAR ROLLER.
If the STRIDING BELT has moved to the left, turn
the left TENSION BOLT 1/4 turn clock-wise and the
right TENSION BOLT 1/4 turn counter-clockwise to
start the STRIDING BELT tracking back to the
center of the REAR ROLLER.
Continued
Life Fitness Model 4000 Treadmill
7
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.
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.
Tensioning an Existing Striding Belt
Step 1
Locate the two BELT TENSIONING BOLTS on each side of the REAR ROLLER MOUNTING BRACKETS. The
TENSIONING BOLTS are accessible from the holes provided in the ENDCAPS.
Step 2
Enter the Manual program and run unit for five minutes at 5.0 mph.DO NOT run on the BELT.
Step 3
Using the speed decrease button ∇, bring the STRIDING BELT speed down to 2 mph. With the STRIDING BELT
speed at 2 mph., tightly grasp the HANDRAILS and attempt to stall the STRIDING BELT. If the STRIDING BELT
slips, continue to 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.
Repeat Step 3.)
8
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.
Step 2
Remove the MOTOR COVER. (See “How To...”).
Step 3
It will now be necessary to relieve the tension on the STRIDING BELT by accessing the TENSIONING BOLTS
from the rear ENDCAPS.
IMPORTANT: EACH ADJUSTMENT MADE TO ONE SIDE OF THE REAR ROLLER MUST BE MET
WITH AN EQUAL ADJUSTMENT TO THE OTHER SIDE OF THE ROLLER TO
MAINTAIN AN IDEAL BELT TENSION AT THE PIVOT POINT.
HELPFUL HINT: MARK THE POSITION OF THE REAR ROLLER ON THE INSIDE OF THE
MOUNTING BRACKET TO LOCATE ITS ORIGINAL PLACEMENT.
THIS WILL HELP WHEN RE-TENSIONING THE STRIDING BELT.
Use a hex key wrench to alternately turn the STRIDING BELT TENSIONING BOLTS 1/4 turn each, counterclockwise until the STRIDING BELT is slackened enough to allow for removal of the FRONT ROLLER in the next
Step.
Step 4
Slide the DRIVE MOTOR PULLEY BELT from the FRONT ROLLER ASSEMBLY PULLEY. Lift the worn FRONT
ROLLER ASSEMBLY from the EXTRUSION BRACKETS and from within the STRIDING BELT to remove it from
the unit.
Step 5
Locate the new FRONT ROLLER ASSEMBLY into position and reverse Steps 1 through 5 to return all parts to
their proper locations.
Step 6
Refer to “How To...ADJUST AND TENSION THE STRIDING BELT” for proper BELT tensioning instructions.
9
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.
Step 2
Remove the MOTOR COVER. See “How To...”
Step 3
Use a phillips screwdriver to remove the three SCREWS securing each of the END CAPS to the FRAME and set
the END CAPS aside.
Step 4
Use a hex key wrench to loosen and
remove the TENSIONING SCREW
and WASHER securing each side of
the REAR ROLLER to the REAR
ROLLER MOUNTING BRACKETS.
HELPFUL HINT: MARK THE
POSITION OF THE REAR ROLLER
ON THE INSIDE OF THE
MOUNTING BRACKET TO
LOCATE ITS ORIGINAL
PLACEMENT.
THIS WILL HELP WHEN RETENSIONING THE STRIDING
BELT.
Step 5
Remove the worn REAR ROLLER
from the machine.
Step 6
Position the new REAR ROLLER against the MOUNTING BRACKETS and use a hex key wrench to install the
TENSIONING SCREWS and WASHERS by alternately turning the SCREWS clockwise an equal number of turns
until the STRIDING BELT is snug, but not overstretched, against the REAR ROLLER.
IMPORTANT: EACH ADJUSTMENT MADE TO ONE SIDE OF THE REAR ROLLER SHOULD BE MET
WITH AN EQUAL ADJUSTMENT TO THE OTHER SIDE OF THE ROLLER TO
MAINTAIN AN IDEAL BELT TENSION AT THE CENTER PIVOT POINT OF THE ROLLER.
Step 7
Reverse Steps 1 through 3 to return all parts to their proper positions and refer to “How To...ADJUST AND
TENSION THE STRIDING BELT” for proper BELT tensioning instructions.
10
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.
Step 2
Remove the VENT COVER. (See “How To...”).
Step 3
Remove the MOTOR COVER. (See “How To...”).
Step 4
Ground yourself to the machine by positioning an ANTI-STATIC GROUNDING STRAP around your wrist and
attaching the other end (alligator clip) to a MOUNTING SCREW, or a connecting GROUND WIRE SCREW.
Step 5
Unplug the six CONNECTORS shown in the illustration from the HEATSINK CONTROL BOARD ASSEMBLY.
NOTE: TAKE A MOMENT TO NOTE THE LOCATIONS OF THE CONNECTORS PRIOR TO UNPLUGGING
THEM FROM THE CONTROL BOARD.
Continued
Life Fitness Model 4000 Treadmill
11
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.
Step 7
Lift off the PROTECTIVE COVER from the top of the CAPACITOR. Remove the
POSITIVE and
NEGATIVE WIRE CONNECTORS leading from the DRIVE MOTOR ASSEMBLY to the CAPACITOR.
NOTE: THE CAPACITOR IS POLARIZED ( + RED, - BLACK ).
Step 8
Remove the two MOUNTING SCREWS securing the HEATSINK CONTROL BOARD ASSEMBLY to the MOTOR
PAN.
Step 9
Carefully lift the malfunctioning HEATSINK CONTROL BOARD ASSEMBLY from
aside.
the machine and set
Step 10
Place the new HEATSINK CONTROL BOARD ASSEMBLY into position and reverse Steps 1 through 8 to return all
parts to their proper locations.
12
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.
Step 2
Remove the VENT
COVER. (See “How
To...”).
Step 3
Remove the MOTOR
COVER. (See “How
To...”).
Step 4
Remove the TRAY if
equipped with the optional
HEART RATE KIT. (See
“How To...”).
Step 5
Remove the Display
Console. (See “How
To...”).
Step 6
Ground yourself to the machine by positioning an ANTI-STATIC GROUNDING STRAP around your wrist and
attaching the other end (alligator clip) to a MOUNTING SCREW, or a connecting GROUND WIRE SCREW.
Step 7
Tuck the 12-PIN CONNECTOR, which was disconnected from the DISPLAY CONSOLE, into the top of the
MONOCOLUMN. Withdraw the DISPLAY WIRE HARNESS from the MONOCOLUMN through the large hole at
the base of the MONOCOLUMN.
Step 8
Unplug the 12-PIN CONNECTOR from the HEATSINK CONTROLLER BOARD ASSEMBLY.
Step 9
Feed the new DISPLAY WIRE HARNESS through the MONOCOLUMN from the large hole at the base of the
MONOCOLUMN until it exits toward the user side of the HANDLEBAR ASSEMBLY which crosses the top of the
MONOCOLUMN..
NOTE: THE 12-PIN CONNECTOR OF THE DISPLAY WIRE HARNESS SHOULD EXIT THE TOP OF THE
MONOCOLUMN ON THE USER SIDE OF THE HANDLEBAR CONNECTING BRACKET TO AVOID ANY
WIRES BEING PINCHED OR DAMAGED BY THE DISPLAY CONSOLE UPON ASSEMBLY.
Step 10
Reverse Steps 1 through 8 to return all parts to their proper positions. Replace any WIRE TIES which may have
been cut to insure the WIRE HARNESS is secure and will not be damaged by moving parts.
Life Fitness Model 4000 Treadmill
13
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. (See “How To...”).
Step 3
Remove the MOTOR COVER. (See “How To...”).
Step 4
Ground yourself to the machine by positioning an ANTI-STATIC GROUNDING STRAP around your wrist and
attaching the other end (alligator clip) to a MOUNTING SCREW, or a connecting GROUND WIRE SCREW.
LIFT ACTUATOR
ES
INCH
5
2
.
m
6
75 c
15.8
LIFT MOTOR NUT
HAIR PIN CLIP
PUSH BOLT
LIFT FRAME ASSEMBLY
HAIR PIN CLIP
CLEVIS PIN
Step 5
Unplug the LIFT ACTUATOR (P4), from the HEATSINK CONTROLLER BOARD ASSEMBLY.
Step 6
Disconnect the large LIFT MOTOR NUT from the pins holding it to the LIFT FRAME ASSEMBLY by removing the
two HAIR PIN CLIPS and PUSH BOLTS.
Step 7
Remove the HAIR PIN CLIP and CLEVIS PIN securing the unthreaded end of the LIFT ACTUATOR to the
FRAME.
Step 8
Carefully lift the malfunctioning LIFT ACTUATOR and remove it from the machine.
Step 9
Check the new LIFT ACTUATOR distance from the top of the threaded post to the center of the hole in the LIFT
MOTOR NUT. The distance should be preset at 6.25 inches (15.875 cm). Position the new LIFT ACTUATOR
ASSEMBLY in place and reverse Steps 1 through 7 to return all parts to their proper locations.
NOTE: BE CAREFUL TO ROUTE WIRES OF THE LIFT ACTUATOR IN A MANNER
WHICH WILL AVOID PINCHING OR DAMAGE TO WIRES BY MOVING PARTS. USE
WIRE TIES TO INSURE WIRES STAY SECURE.
14
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.
Step 2
Remove the VENT COVER. (See “How To...”).
Step 3
Remove the MOTOR COVER. (See “How To...”).
Step 4
It will now be necessary to relieve the tension of the STRIDING BELT to allow removal of the DRIVE MOTOR
BELT from the FRONT ROLLER.
HELPFUL HINT: REMOVE THE END CAPS AND MARK THE POSITION OF THE REAR ROLLER ON THE
INSIDE OF THE MOUNTING BRACKET TO LOCATE ITS ORIGINAL PLACEMENT.
THIS WILL HELP WHEN RE-TENSIONING THE STRIDING BELT.
Using a hex key wrench, ALTERNATELY loosen the two TENSIONING SCREWS and WASHERS securing each
side of the REAR ROLLER to the REAR ROLLER MOUNTING BRACKETS an EQUAL number of times counter
clockwise until the STRIDING BELT is slackened enough to allow for partial removal of the FRONT ROLLER.
IMPORTANT: EACH ADJUSTMENT MADE TO ONE SIDE OF THE REAR ROLLER SHOULD BE MET
WITH AN EQUAL ADJUSTMENT TO THE OTHER SIDE OF THE REAR ROLLER TO
MAINTAIN AN IDEAL STRIDING BELT TENSION AT THE CENTER PIVOT POINT OF THE
REAR ROLLER UPON RE-TENSIONING.
Continued
Life Fitness Model 4000 Treadmill
15
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.
Step 6
Position a new DRIVE MOTOR BELT over the DRIVE MOTOR and FRONT ROLLER PULLEYS taking note to
properly align the ribs within the grooves of the PULLEYS. Relocate the FRONT ROLLER back into operating
position.
Step 7
Use a hex key wrench to tighten the TENSIONING SCREWS and WASHERS at the REAR ROLLER by
ALTERNATELY turning the SCREWS clockwise an EQUAL number of times each until the STRIDING BELT is
snug, but not overstretched, against the REAR ROLLER.
Step 8
Check the tension of the DRIVE BELT using a BELT TENSIONING GUAGE. (Belt tension=100 lb+/-5 lb). The
DRIVE BELT tension can be adjusted by loosening or tightening the LOCK NUT of the TENSIONING BOLT
located next to the LIFT ACTUATOR.
Step 9
Reverse Steps 1 through 4 to return all parts to their proper positions and refer to “How To...ADJUST AND
TENSION THE STRIDING BELT” for proper BELT tensioning instructions.
CHECKING THE DRIVE BELT PULLEY ALIGNMENT:
It is a good practice to check the alignment of the DRIVE MOTOR BELT PULLEY and the FRONT ROLLER
PULLEY whenever servicing or replacing the DRIVE MOTOR BELT. With the power switch OFF and the machine
unplugged from the electrical outlet, lay a straightedge flat against the outside of the FRONT ROLLER PULLEY
and the DRIVE MOTOR PULLEY. The flat faces of the two PULLEYS should be in-line (coplanar). If the PULLEYS
are not in-line, loosen the two DRIVE MOTOR PULLEY SET SCREWS and adjust the DRIVE MOTOR PULLEY on
the MOTOR SHAFT accordingly. Tighten the SET SCREWS to secure the PULLEY into position.
16
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.
Step 2
Remove the VENT COVER. (See “How To...”).
Step 3
Remove the MOTOR COVER. (See “How To...”).
Step 4
Cut the WIRE TIE that secures the three DRIVE MOTOR ASSEMBLY lead wires and the SENSOR CABLE at the
MOTOR HOUSING. Note the location of this WIRE TIE for replacement later. Disconnect the three DRIVE
MOTOR lead wires from the MOTOR TERMINALS. Note lead wire positions for reference during installation.
(Orientation = Black, Green, Red, clockwise when facing FLYWHEEL).
Step 5
Detach the SENSOR CABLE from the black retaining clip (attached to the metal heat sink on the CONTROL
BOARD ASSEMBLY). Disconnect the SENSOR CABLE CONNECTOR from the CONTROL BOARD. Note the
orientation of the SENSOR CABLE CONNECTOR on the CONTROL BOARD for reference during installation.
Step 6
It will now be necessary to relieve the DRIVE MOTOR BELT tension by removing the LOCK NUT on the
TENSIONING BOLT located next to the LIFT ACTUATOR.
NOTE: IF A BELT TENSIONING GUAGE IS NOT AVAILABLE, MARK THE CURRENT SETTING OF THE
TENSIONING BOLT BY LOCATING A PIECE OF TAPE ON THE BOLT AGAINST THE BRACKET ON
THE OPPOSITE SIDE OF THE LOCK NUT. ALSO, COUNT AND NOTE THE NUMBER OF TURNS
REQUIRED TO REMOVE THE LOCK NUT. THIS WILL AID IN PROPERLY TENSIONING THE DRIVE
BELT DURING INSTALLATION.
Remove the 1/4-20 nylon-insert LOCK NUT from the TENSIONING BOLT. Pivot the MOTOR MOUNTING
BRACKET rearward and remove the DRIVE MOTOR BELT from the MOTOR PULLEY.
Continued
17
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.
Pivoting the MOTOR MOUNTING BRACKET may be required to remove the ASSEMBLY.
Step 8
Align the new DRIVE MOTOR ASSEMBLY with the MOTOR MOUNTING BRACKET. Locate the new DRIVE
MOTOR ASSEMBLY into position and secure IN PLACE with the two SCREWS. (Support the DRIVE MOTOR
ASSEMBLY with one hand beneath it while inserting the SCREWS with the other hand). Install the DRIVE
MOTOR BELT onto the DRIVE MOTOR PULLEY. Be sure the DRIVE BELT properly engages all ribs on both the
DRIVE MOTOR and the FRONT ROLLER PULLEYS.
Step 9
Check that the SHAFT KEY located on the DRIVE
MOTOR SHAFT is properly seated within one of the four
KEY slots in the PLASTIC FAN and that the PLASTIC
FAN rests against the shoulder in the MOTOR SHAFT.
Reposition the SHAFT KEY and FAN as required if they
are not properly aligned.
Step 10
Use a STRAIGHT-EDGE to align the flat sides of the
DRIVE MOTOR PULLEY and the FRONT ROLLER
PULLEY. The faces of the two PULLEYS should be inline (coplanar). If the PULLEYS are not aligned, loosen
the two SET SCREWS on the DRIVE MOTOR PULLEY
and adjust as necessary. Once aligned, recheck the
SHAFT KEY and PLASTIC FAN positions per Step 9
above and tighten the two DRIVE MOTOR PULLEY SET
SCREWS.
Step 11
Install the 1/4-20 nylon-insert LOCK NUT onto the
TENSIONING BOLT and, if available, use a belt tensioning gauge to tension the DRIVE MOTOR BELT to 100 lb
(+/- 5 lb).
Step 12
NOTE: IF A GAUGE IS NOT AVAILABLE, RE-INSTALL THE LOCK NUT BY TURNING IT THE SAME
NUMBER OF TIMES IT WAS TURNED ON REMOVAL. BE SURE THE TENSIONING BOLT IS POSITIONED
PROPERLY IN THE SLOT AT THE FRONT OF THE MOTOR HOUSING DURING TENSIONING.
Connect the three DRIVE MOTOR lead wires to the proper DRIVE MOTOR TERMINALS (See Step 4). Attach the
new SENSOR CABLE to the black retaining clip. Connect the SENSOR CABLE CONNECTOR to the CONTROL
BOARD terminal. Install a new WIRE TIE to secure the SENSOR CABLE and the three DRIVE MOTOR LEAD
WIRES in the same location from which the previous WIRE TIE was removed.
Step 13
Manually rotate the DRIVE MOTOR SHAFT. Check that all wiring is adequately dressed to clear rotating
components. Redress wiring if required.
Step 14
Reverse Steps 1 through 3 to return all parts to their proper positions.
18
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.
Step 2
Remove the MOTOR COVER.
(See “How To...”).
Step 3
Remove the DECK and STRIDING
BELT. (See “How To...”).
Step 4
Insert a hex key wrench into the access
hole
located
on
top
of
the
LIFESPRING. Loosen and remove the
SCREW through the access hole.
Step 5
Lift the entire LIFESPRING/ANTIROTATION CLIP ASSEMBLY from the
machine. Slide the worn LIFESPRING
out of the ANTI-ROTATION CLIP and
replace with a new LIFESPRING.
Step 6
Reposition the LIFESPRING/ANTIROTATION CLIP ASSEMBLY in place
taking note that the lower lip of the
ANTI-ROTATION CLIP rests against
the FRAME of the Treadmill. Secure
the ASSEMBLY in place with the
SCREW.
Step 7
Reverse Steps 1 through 3 to return all parts to their proper locations. Refer to “How To...Adjust and Tension the
Striding Belt” for proper STRIDING BELT tensioning instructions.
19
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. Hold on to
the TRAY during this procedure to prevent the
TRAY from falling and possibly damaging the
WIRE HARNESS.
Step 3
Swing the TRAY slowly away from the back of
the DISPLAY CONSOLE while the extended
arms of the TRAY continue to rest on the
HANDLEBARS of the treadmill.
Step 4
Unplug the 3-PIN CONNECTOR of the Heart
Rate Monitor Receiver HARNESS (located
within the TRAY) from the matching 3-PIN
CONNECTOR on the back of the DISPLAY
CONSOLE.
Step 5
Swing the TRAY down while lifting the
extended arms of the TRAY from the HANDLEBARS and remove from the machine. Reverse Steps 1 through 4 to
replace the TRAY and restore all parts to their original positions.
NOTE: THE RED DOT ON THE HEART RATE MONITOR RECEIVER PLUGGED IN TO THE
RECEPTACLE INSIDE THE TRAY SHOULD ALWAYS FACE TOWARD THE USER.
20
Life Fitness Model 4000 Treadmill
NOTES:
21
Life Fitness Model 4000 Treadmill
WIRING DIAGRAM
Life Fitness Model 4000 Treadmill
1
PARTS IDENTIFICATION
SN # 558000 - UP
Overlay Bezel
AK40-00058-0001 Eng/Eng
AK40-00058-0004 Frn/Met
Console Assembly
AK40-00057-0001(R) Eng/Met
AK40-00057-0004(R) Frn/Met
Handlebar w/Grips
OK40-01092-0001
Mono-Column
OK40-01093-0001
Stop Key/Clip
AK40-00035-0000
Motor Shroud
AK40-00037-0002
Handrail Tube
OK40-01006-0001
Wheel
OK40-01021-0000
Leg Leveler
0017-00009-0796
2
Life Fitness Model 4000 Treadmill
PARTS IDENTIFICATION
SN # 558000 - UP
Extrusion(RT)
OK40-01165-0001
Extrusion(LT)
OK40-01165-0002
End Cap(RT)
OK40-01086-0007
End Cap(LT)
OK40-01086-0008
Tray w/Heart Rate(optional)
GK40-00002-0006
Tray(optional)
OK40-01095-0001
Telemetry Receiver
SK40-00045-0001
Handrail Mount
OK40-01034-0001
Display Cable
AK36-00017-0000
Vent Cover
AK40-00039-0001
Push-Cap Kit
ON/OFF Switch
GK45-00002-0008
AK40-00052-0000
Removable Safety Switch
0017-00032-0191
3
4
Transformer
0017-00003-0751(120v)
0017-00003-0758(230v)
Heatsink Assembly
SK40-00033-0001(R) 120v/60Hz
AK40-00033-0002(R) 220v/60Hz, 240v+
Lift Actuator
OK40-01132-0000(120v/60Hz)
OK40-01132-0001(220v/50Hz, 240v+
Optical Sensor
AK40-00031-0000
Drive Motor Assembly
SK40-00051-0001 (120v/60Hz)
AK40-00051-0002 (220v/50Hz, 240v+)
Front Roller Assembly
AK40-00027-0000
Lift Pin Kit
GK45-00002-0009
Deck Assembly
AK40-00025-0001
Rear Roller
OK40-01013-0000
Stride Belt
OK40-01177-0000
Drive Belt
OK40-01014-0000
TECKS PAK
OK40-01026-0001
Life Fitness Model 4000 Treadmill
PARTS IDENTIFICATION
SN # 558000 - UP
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. 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.
5
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 RECEIVED:
TIME COMPLETED:
TECHNICIAN NAME:
CUSTOMER SUPPORT SERVICES
10601 W. Belmont Ave., Franklin Park IL 60131 PHONE (800) 351-3737 Toll Free or (847) 451-0036
FAX (800) 216-8893 Toll Free or (847) 288-3702
6
Life Fitness Model 4000 Treadmill
NOTES:
7