FreeClimber Systems Owner’s Manual ®
Printed in the United States. ® ©1997 StairMaster Sports/Medical Products, Inc. All rights reserved. Corporate Headquarters 12421 Willows Road N.E., Suite 100 Kirkland, WA 98034 (800) 635-2936 (425) 823-1825 Fax (425) 823-9490 www.stairmaster.com P/N 22569-E © 1997 StairMaster Sports/Medical Products, Inc., StairMaster and FreeClimber are registered trademarks or trademarks of StairMaster Sports/Medical Products, Inc. in the United States and /or other countries.
10 REASONS WHY MORE HEALTH AND FITNESS FACILITIES CHOOSE STAIRMASTER® EQUIPMENT OUTSTANDING QUALITY Equipment you can depend upon, week after week, for heavy commercial use – instead of a sign that says "out of order." EXCEPTIONAL PERFORMANCE Generates exceptional customer satisfaction – allowing you to retain existing club members and attract new ones. IMMEDIATE CUSTOMER RECOGNITION An excellent first impression is critical to attracting new club members to your facility.
A FULL LINE OF EXCEPTIONAL PRODUCTS STAIRCLIMBERS The Best in the Industry ELLIPTICAL STRIDING SYSTEMS The New StairMaster FreeRunner Our popular FreeClimber® stairclimber line now offers you 5 different models to choose from.
A FULL LINE OF EXCEPTIONAL PRODUCTS TREADMILLS The Highest Quality STRATUS EXERCISE BIKES New Models & Prices In response to many requests we received from our customers for a high quality treadmill, StairMaster® has selected the Quinton® treadmill as a new addition to our product line – with four different models to choose from – the ClubTrack® 510, the ClubTrack® 510 Plus, the ClubTrack® 612 and the ClubTrack® 612 Plus.
A FULL LINE OF EXCEPTIONAL PRODUCTS CROSSROBICS® The Ultimate Exercise Machines The StairMaster® Crossrobics products are innovative machines that combine aerobic exercise with a weight stack for strength conditioning. Available only from StairMaster, the Crossrobics machines provide the ultimate workout. StairMaster offers you two Crossrobics machines – the Crossrobics 1650 LE and the Crossrobics 2650 UE Kayak.
WARRANTY This is to certify that the StairMaster® FreeClimber® exercise system is warranted by StairMaster Sports/Medical Products, Inc. to be free of all defects in materials and workmanship. This warranty does not apply to any defect caused by negligence, misuse, accident, alteration, improper maintenance, or an “act of God”. This warranty is non-transferable from the original owner.
PREFACE Regular use of the Stairmaster® FreeClimber® exercise system is a safe and effective way to develop aerobic fitness while conditioning the major muscles of the lower body. In order to get the best results, and to keep your machine in peak operating condition, you should carefully read and follow the guidelines presented in this manual. WHAT IS IN THIS MANUAL? The first part of this manual includes sections on safety, installation, operating instructions, and preventive maintenance.
CONTENTS SAFFETY GUIDELINES ........................................................................................ 1 INTRODUCTION ................................................................................................... 3 INSTALLATION INSTRUCTIONS ........................................................................ 6 BASIC OPERATING INSTRUCTIONS ................................................................ 9 General Guidelines for Safe Operation ...........................................
CONTENTS FREECLIMBER 4200 PT CONSOLE ................................................................... 28 Top Window .................................................................................................. 28 Workout Setup ...................................................................................... 28 Timer ...................................................................................................... 30 Bottom Window .............................................................
CONTENTS Mechanical Troubleshooting ......................................................................... 45 PARTS REMOVAL AND REPLACEMENT ........................................................ 48 Covers ............................................................................................................ 48 Mid Cover .............................................................................................. 48 Top Cover ........................................................................
CONTENTS LIST OF TABLES Table 1. Dimensions and Specifications for the StairMaster® FreeClimber® Exercise Systems .................................. 5 Table 2. Fitness Rating Norms (METs) ........................................................... 20 Table 3: Character Codes for the Scrolling Message ................................... 25 Table 4. Console Codes ................................................................................. 27 Table 5. Recommended Preventive Maintenance Schedule ..........
SAFETY GUIDELINES WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS: IMPORTANT SAFETY INSTRUCTIONS ! This symbol appearing throughout this manual means Attention! Be Alert! Your safety is involved. The following definitions apply to the words “Danger” and “Warning” found throughout this manual: DANGER - Used to call attention to IMMEDIATE hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.
SAFETY GUIDELINES 4. Use this machine only for its intended use as described in this Manual. Do not use parts, attachments, or accessories other than those provided by StairMaster® Sports/Medical Products, Inc. 5. Do not use the external power supply if it has a damaged cord or plug, if it is not working properly, if it has been dropped or damaged, or dropped into water. Contact our Customer Service Department to arrange for the return of damaged parts.
INTRODUCTION Before leaving the manufacturing facility in Tulsa, Oklahoma, your StairMaster® FreeClimber® exercise system was thoroughly inspected and tested to ensure proper operation. The major parts of the machine are shown in Figures 1 and 2.
INTRODUCTION Figure 2: Major Parts - 4400 PT/CL Page 4
INTRODUCTION Throughout this Manual, all references to the left or right side and to the front or back are made as if you were on the machine, ready to exercise. For example, the console is located on the front of the machine. The dimensions and general specifications of the machines are listed in Table 1. Table 1.
INSTALLATION INSTRUCTIONS Assemble your machine before use. Machines shipped outside the United States need to be uncrated before they can be assembled; refer to the “Uncrating Instructions” included with your machine for the details. 1. Remove all shipping material from your machine once it is in place. 2. Make sure the machine is level before you use it for the first time. The four rubber end caps (see Figure 3) are designed to compensate for uneven floors.
INSTALLATION INSTRUCTIONS 4. If you have a 4600/4400 CL, skip to step 9. If you have a 4600/4400/ 4200 PT, connect the DC cable of the power supply to the connector near the bottom of the left side cover (see Figure 4). Figure 4: DC Power Connector 5. Place the power supply on the floor near an AC wall outlet. To reduce the hazard of electrical shock, place the power supply in a location away from the machine and away from exposure to perspiration.
INSTALLATION INSTRUCTIONS 6. Check to be sure that the input AC power rating marked on the power supply matches the available power. If it does not, obtain the matching power supply from StairMaster® Sports/Medical Products, Inc. before proceeding any further. ! WARNING TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO PREVENT SEVERE DAMAGE TO THE MACHINE, USE ONLY THE POWER SUPPLY APPROVED FOR USE WITH THIS EQUIPMENT. IN ADDITION, YOUR MACHINE MUST BE PROPERLY GROUNDED. 7.
BASIC OPERATING INSTRUCTIONS GENERAL GUIDELINES FOR SAFE OPERATION ! WARNING THESE GUIDELINES ARE DIRECTED TO YOU, AS THE OWNER OF THE MACHINE. YOU SHOULD INSIST THAT ALL USERS FOLLOW THE SAME GUIDELINES. YOU SHOULD MAKE THIS MANUAL AVAILABLE TO ALL USERS. 1. Obtain a complete physical examination from your medical doctor and enlist a health/fitness professional’s aid in developing an exercise program suitable for your current health status. 2.
BASIC OPERATING INSTRUCTIONS YOUR FIRST WORKOUT ON THE STAIRMASTER® FREECLIMBER® EXERCISE SYSTEM The ATTRACT Mode All workouts on the StairMaster FreeClimber exercise system start from the ATTRACT mode. The 4600/4400 PT/CL console displays an EKG signal or scrolls a message in the text bar when it is in the ATTRACT mode. You must step on the 4600/4400 CL pedals before the console goes into the ATTRACT mode. The 4200 PT console displays a moving line in the upper LCD window when it is in the ATTRACT mode.
BASIC OPERATING INSTRUCTIONS 2. The console will prompt you to enter your body weight. Enter your weight in pounds (or kilograms if the console is set up for metric units). Correct entry errors by pressing [CLEAR] before you press [ENTER]. 3. The console will prompt you to enter the workout time in one minute increments between five and 60 minutes. Press [1], [0], [ENTER] to exercise for ten minutes. If you do not start exercising within 30 seconds, the console will return to the ATTRACT mode.
BASIC OPERATING INSTRUCTIONS 4. Select an intensity level that allows you to stay in the middle of the pedal range of motion. Faster is not always better. Exercise at a level that is consistent with your fitness level. 5. 4600/4400 PT: You can stop and rest as many times as necessary for up to two minutes at each rest period during all programs except the Constant Heart Rate program, which has unlimited fifteen second rest periods.
CONTACT HEART RATE (4600 PT/CL) The StairMaster® FreeClimber® features a digitized contact heart rate monitoring system. Through the use of stainless steel sensors built into the upper handles and sophisticated software, heart rate can be checked at any time during a workout. The heart generates a rhythmic, electronic signal each time it beats (the electrocardiogram or EKG signal). The sensors detect this electrical signal through the hands when the sensors are gripped during a workout.
POLAR® HEART RATE (4600/4400 PT/CL ONLY) The StairMaster® FreeClimber® 4600/4400 PT/CL features Polar® heart rate monitoring. The system consists of the receiver, located on the stepper, and a transmitter belt (purchased separately), worn across your chest. The transmitter belt senses the heart beat and sends a signal to the receiver. Your heart rate, in beats per minute, is shown on the console text bar. The transmitter belt attaches an identification number to your heart rate signal.
FREECLIMBER 4600/4400 PT/CL CONSOLE The StairMaster® FreeClimber® 4600/4400 PT/CL console is divided into four sections: the text bar, display, the function keypad, and the exercise program keypad (see Figures 6 &7).
FREECLIMBER 4600/4400 PT/CL CONSOLE TEXT BAR Information regarding workout statistics and data entry is displayed or scrolled across the text bar. A countdown timer is located directly above the words "Interval Time". The timer shows the number of seconds remaining in the current interval. DISPLAY A profile of all exercise programs (except MANUAL and FIT TEST) appears in the display when you press its key. The taller the column, the faster the climbing speed for that interval.
FREECLIMBER 4600/4400 PT/CL CONSOLE Intensity Level. Shows the current level between 1 (the easiest) and 20 (the hardest). Shows the number of lights in the Manual program between 1 and 14. METs. Gives you the relative energy cost of exercise. MET stands for multiples of the resting metabolic rate. While you are sitting quietly, your body consumes oxygen at the rate of about 3.5 milliliters per kilogram of body mass per minute. When you exercise, your body needs more oxygen in order to function.
FREECLIMBER 4600/4400 PT/CL CONSOLE Stop. If pressed at any time, the console will return to the ATTRACT mode. Workout Stats. If pressed during your workout, all workout statistics continuously scroll across the text bar. Press any key to stop scrolling at that statistic. If pressed immediately after your workout, the workout summary statistics will scroll once across the text bar. Press any key to stop scrolling at that statistic.
FREECLIMBER 4600/4400 PT/CL CONSOLE After the profile is scrolled, the prompts are: • • • • “PRESS ENTER KEY TO ACCEPT” “ENTER BODY WEIGHT” -- type in your body weight in pounds (or kilograms if your console is set to metric units). “ENTER LEVEL 1 - 20” -- select your intensity level with level 1 being the easiest and level 20 the hardest. “ENTER TIME 5 - 60” -- select the workout duration in one minute increments from five to 60.
FREECLIMBER 4600/4400 PT/CL CONSOLE Note: Keep stepping until the end of the Fit Test. The Fit Test will end if you stop stepping. The console will prompt you to find your pulse; use the artery below your thumb in your wrist or the artery in the side of your neck. Start counting the beats when the console prompts you—the first beat you feel is zero and then one and so on. Enter the number of beats you counted in the ten seconds.
FREECLIMBER 4600/4400 PT/CL CONSOLE Preset Exercise Programs 4600 PT/CL: There are four preset exercise programs. The exercise speed during the programs varies automatically over 14 increments within each of the 20 different intensity levels. Varying the intensity of an exercise program does not change the profile shown on the display. Change the intensity level of your workout by pressing [+ INCREASE] or [- DECREASE]. For each level, the average energy cost of all programs is about the same.
FREECLIMBER 4600/4400 PT/CL CONSOLE The FAT BURNER program is a 60 interval workout designed for people just starting a weight control program. The FAT BURNER PLUS program is similar but has 90 intervals. It is meant for the longer workouts you will need as your fitness level increases. The STEADY PACE and ROLLING HILLS programs are 30 interval workouts with gradual speed changes. They are geared for those who are just starting to exercise or for those who need an easy day of recovery exercise.
FREECLIMBER 4600/4400 PT/CL CONSOLE Turning the Jackpot Option On and Off 1. The computer must be in the ATTRACT mode. Press [INCREASE], [7707], [ENTER]. 2. The prompt “ENTER ODDS” will appear in the console display. Enter the numeric odds you have selected, between 1 and 999. 3. The jackpot results are saved in the console memory until the next workout is started. Press [WORKOUT STATS] to review the results. 4.
FREECLIMBER 4600/4400 PT/CL CONSOLE taller or shorter. Press [ENTER] to move one column to the right and [CLEAR] to move one column to the left. 4. When all of the intervals are correctly programmed, press [0- 4600 PT/CL] or [YES - 4400 PT/CL] to save the profile. Press [STOP - 4600 PT/CL] or [START/STOP - 4400 PT/CL] to abort the programming process without saving the profile. Using a Custom Program 1. Press [- DECREASE] and the exercise program keypad button you assigned to the custom program. 2.
FREECLIMBER 4600/4400 PT/CL CONSOLE Table 3: Character Codes for the Scrolling Message Character Code Character Code Character Code 0 1 2 3 4 5 6 7 8 9 SPACE A B C D E F G H I J K L 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 M N O P Q R S T U V W X Y Z Ä Ü Ö ß Å Á Ó É Ñ 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Í À Î È Â Ç Ê ¿ + $ .
FREECLIMBER 4600/4400 PT/CL CONSOLE 4. To edit multiple characters at one time, press [9], [9], [ENTER] to erase all of the characters to the right of the last character displayed on the text bar. 5. To erase the entire message, press [+ INCREASE], [1], [0], [5], [ENTER] while in the ATTRACT mode. 6. The edited message will scroll across the text bar. If you have erased the entire message, the text bar area will be blank during the ATTRACT mode. 7.
FREECLIMBER 4600/4400 PT/CL CONSOLE Table 4.
FREECLIMBER 4200 PT CONSOLE The StairMaster® FreeClimber® 4200 PT console is divided into two LCD display windows. There is a four-function keypad located below the bottom window (see Figure 8). While you are exercising, the bottom window scrolls through a display of four workout statistics. An arrow on the side of each LCD window points to the name of what is being displayed. Figure 8: 4200 PT Console Diagram TOP WINDOW The top LCD window displays information while you set up your workout.
FREECLIMBER 4200 PT CONSOLE 2. The arrow pointing to the word "Program" should be flashing and "P1" should be displayed. P1 corresponds to the MANUAL program. Use the [+ or - ARROW] to change the workout option. "P2" corresponds to Steady Pace, "P3" to Fat Burner, and "P4" to Aerobic Training. The different workout option profiles are shown on the right side of the console. 3. When the correct workout option is displayed on the top LCD window, press [ENTER/SELECT]. 4.
FREECLIMBER 4200 PT CONSOLE Timer During your workout, the top window keeps track of your workout time in minutes and seconds. The display arrow points to the word "Time" on the console. You may rest for up to 30 seconds at any time during your workout. Either stop stepping or press [START/STOP] to begin your rest period. To resume your workout, step on the pedals. If you press [START/STOP] during a rest period, or if you rest for more than 30 seconds, the console will return to the ATTRACT mode.
FREECLIMBER 4200 PT CONSOLE Keypad ENTER/SELECT. During workout setup, press this key to enter your personal information and then move to the next entry. During your workout, press this key to lock the bottom display window on any one statistic or to return to the scrolling mode. + or - ARROWS. During workout setup, press these keys to adjust your personal information before you press [ENTER/SELECT]. During your workout, use these keys to adjust the level (or climbing speed). START/STOP.
MAINTENANCE INSTRUCTIONS HELPFUL HINTS Read all maintenance instructions thoroughly before beginning work. In some cases, an assistant is required to perform the necessary tasks. All references to the right or left side and to the front or back are made as if you were on the machine ready to exercise. For example, the console is located on the front of the machine. Major component names and locations are shown in Figure 10.
MAINTENANCE INSTRUCTIONS The 4200 PT console keeps track of the number of hours the machine was used and the total number of floors climbed. From the ATTRACT mode, press [+ ARROW] and then double-click [RESET]. The hours are shown in the top LCD window and the total floors are shown in the bottom LCD window. INITIAL SERVICE Upon receiving your machine, use a soft, clean towel to wipe off the dust which may have accumulated during shipping. Your new machine will require minor assembly.
MAINTENANCE INSTRUCTIONS 2. Inspect the Poly-V belt and HTD belts for excessive wear during the quarterly lubrication. Adjust the belt tension if necessary. LUBRICATION There are nine components that need periodic lubrication: the drive chain, the step chains, the pedal arm return springs, the step chain connection points, the pedal arm bushings, the leveling arm bushings, the spring pulley shafts, the pedal shafts and the leveling arm pins. These parts are shown in Figure 10.
MAINTENANCE INSTRUCTIONS shafts with a dry cloth. Protect the shafts from corrosion with a thin coat of multi-purpose grease before reassembling. 8. Remove the pedals every three months. Clean the pedal shaft and leveling arm pin with a dry cloth. Protect the pedal shaft and leveling arm pin from corrosion with a light coat of multi-purpose grease before reassembling. ! WARNING TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE THE PEDAL AREA IS FREE OF GREASE OR OIL.
MAINTENANCE INSTRUCTIONS Table 5.
TROUBLESHOOTING GENERAL TROUBLESHOOTING GUIDELINES This troubleshooting section is organized into three basic problem sections: electrical troubleshooting, console diagnostics, and mechanical troubleshooting. Once you have identified the problem section, perform all the tests in the same order as written. To order a replacement part or for help with troubleshooting, contact our Customer Service Department. Refer to the Appendix for the appropriate phone number.
ELECTRICAL TROUBLESHOOTING 5. Follow the white power connector wire to the where it plugs into the main cable white wire, and disconnect it from the main cable white wire. 6. Set your voltmeter to VDC. Connect the positive lead of your voltmeter to the white wire from the power connector and touch the gray casing of the alternator with the negative lead of your voltmeter. 7. DC voltage measured should be 12 - 19 VDC. Replace the power connector if the voltage is not the same value as in step 3.
ELECTRICAL TROUBLESHOOTING Diode Test 13. Remove the brown wire and diode from the field terminal of the alternator and set your voltmeter to the Ohms setting. 14. Place one lead from the voltmeter on each end of the diode, and then reverse the leads. A diode that is good will show a high reading in one direction and a low reading when the leads are reversed. Replace the diode if the readings recorded are both high or both low. Resistor Test 15.
ELECTRICAL TROUBLESHOOTING Alternator Test 5.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS The following tests are performed while the console is in the DIAGNOSTIC mode. While the console is in the ATTRACT mode, and without stepping on the pedals, press [+INCREASE], [1], [0], [7], [ENTER] to activate the DIAGNOSTIC mode. The numbers will not appear on the display as you enter them. If the console fails any test, the console should be replaced or exchanged. To return to the ATTRACT mode, press either [CLEAR] or [START/STOP] while in the DIAGNOSTIC mode.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS keypad or the function keypad will light an LED within the outline on the display that corresponds to that button's position on the console. 3. Firmly press each button. If the LED corresponding to the button you pushed does not light up, the keypad is bad and the console should be replaced. 4. Press [CLEAR] to test the LED and then end the test 10 seconds later. Speed Test Use this test to verify the electronic speed control routines of the console.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS Contact Heart Rate Test (4600/4400 PT/CL only) The contact heart rate system is made up of the console and the contact heart rate handles. You can test each component by performing the following steps: 1. While the console is in the ATTRACT mode (noted by a simulated EKG signal in the console display), or at the “SELECT A WORKOUT” prompt, press [+INCREASE], [1], [0], [8], [ENTER]. 2.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS 2. While the console is in the ATTRACT mode (noted by a simulated EKG signal in the console display), or at the “SELECT A WORKOUT” prompt, press [+INCREASE], [1], [0], [8], [ENTER]. 3. A flashing ♥ should be displayed in the console text bar. Your heart rate, in beats per minute, will show next to the heart icon.
MECHANICAL TROUBLESHOOTING If you hear a grinding or clicking noise, or experience excessive vibration during exercise, or if the pedals are not functioning properly, you probably have a problem in the drive train. Attempt to isolate the problem area by performing the following tests in precisely the order listed below. Refer to the “Parts Removal and Replacement” section for all disassembly and assembly instructions. 1. Unplug the machine and remove the bottom side covers.
MECHANICAL TROUBLESHOOTING 4. Remove the drive and step chains. Check the condition of the chains by flexing each link up and down. Each link should move freely. Replace the chain if any stiff or inflexible links are found or if the chain is rusty, corroded or otherwise damaged. Do not reinstall the chains. 5. Remove the pedals. Clean any corrosion off the pedal shaft with an oildampened rag. Apply a thin coat of multi-purpose grease to the shaft. If the noise persists, go to step 6. 6.
MECHANICAL TROUBLESHOOTING 9. Remove the HTD belt. Inspect the belt, the Poly-V pulley and the HTD pulley for excessive wear. Replace if necessary. The Poly-V pulley should spin freely. If it does not, replace the eccentric shaft assembly. 10. Inspect the HTD pulley for excessive wear and smoothness of operation. If the pulley is worn, replace it. If it does not spin freely, remove the first reduction shaft and inspect the bearings. 11.
PARTS REMOVAL AND REPLACEMENT COVERS ! WARNING TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE THE COVERS ARE REMOVED. DO NOT DEPRESS OR RAISE THE PEDALS WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE. There are three covers on the 4400 PT/CL and the 4200 PT: the top cover, the mid cover and the bottom cover. The top and bottom covers are made of a right and left section. Do not separate the right and left sections of either the top or bottom covers to perform most maintenance tasks.
PARTS REMOVAL AND REPLACEMENT 5. 4600 PT/CL: Use the fastener removal tool to release the cover fasteners and separate the top covers. 6. To reinstall the 4400 PT/CL and 4200 PT fasteners, remove the pin completely from the base. Insert the base into the hole in the covers. Insert the pin into the base until it is flush with the base. Shield (4600 PT/CL ) 1. Remove the two mounting screws from the bottom shield. 2.
PARTS REMOVAL AND REPLACEMENT CONSOLE 1. Remove the four mounting knobs from the back of the console. 2. Disconnect the main cable, contact heart rate cables (4600 PT/CL), and Polar® cable (4600/4400 PT/CL) from the back of the console. Lift the console off the machine. 3. Reverse the steps to reinstall the console. CONSOLE ADJUSTMENT 1. Loosen the console bracket wing nut. 2. Pivot the console up or down to adjust the console to desired viewing angle and then tighten the wing nut.
PARTS REMOVAL AND REPLACEMENT 6. Adjust the HTD belt tension so that you have 1/4 inch (0.6 cm) of sideto-side play with fingertip pressure (see Figure 30). The bottom shaft is mounted in an eccentric hub. To adjust the tension: • • • • Loosen and remove the four bolts and nyloc nuts from the hub. Turn the hub one hole clockwise. Install and tighten the four bolts and nyloc nuts. Verify the HTD belt tension. 7. Install the Poly-V belt. Make sure it is centered on the pulleys. 8.
PARTS REMOVAL AND REPLACEMENT 4. Check to ensure that the spring pulley turns freely and is not worn excessively. Refer to the “Spring Pulley” section if you have to replace the pulley. 5. To reinstall the spring, connect it to the end of the step chain using the master link. 6. Route the spring under the spring pulley that is fastened to the spring pulley shaft (see Figure 10). 7. Hook the end of the pedal arm return spring onto the spring hanger.
PARTS REMOVAL AND REPLACEMENT SPRING PULLEY 1. Remove the bottom cover. 2. Unhook the pedal arm return spring from the spring hanger. 3. Remove the snap ring from the pulley shaft (see Figure 10). ! WARNING TO REDUCE THE RISK OF EYE INJURY, WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS. 4. Slide the pulley and washer off the shaft. 5. Before reinstalling the pulley, clean the pulley shaft thoroughly with a clean, dry cloth. Apply a thin coat of multi-purpose grease to the pulley shaft. 6.
PARTS REMOVAL AND REPLACEMENT 2. Remove the master link from the drive chain. 3. Remove the drive chain from the sprockets. 4. Reinstall the drive chain, ensuring the master link is properly installed. 5. Check the drive chain tension. There should be a total of 1 to 1-1/2" (2.5 to 4.0 cm) of play, up and down, at the slackest point in the chain (see Figure 29). If the drive chain tension needs adjustment, refer to the “Drive Hub Assembly” section.
PARTS REMOVAL AND REPLACEMENT 5. Remove the drive chain. 6. Remove the sprocket and the other small parts from the left side of the hub assembly (see Figure 21). 7. Slide the drive shaft to the right, out of the hub assembly. If you remove the right-hand clutch sprocket from the drive shaft, do not confuse it with the left-hand clutch sprocket. 8. Loosen and remove the two remaining bolts and nuts that hold the hub assembly to the frame. Remove the hub assembly. 9.
PARTS REMOVAL AND REPLACEMENT PEDAL 1. Remove the snap ring and flat washer from the leveling arm pin and the pedal shaft (see Figure 20). ! WARNING TO REDUCE THE RISK OF EYE INJURY, WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS. 2. Slide the pedal off the shaft. 3. Clean the pedal shaft and leveling arm pin with a dry cloth. Lubricate the pedal shaft and the leveling arm pin with a thin coat of multipurpose grease. 4. Reverse the procedures to reinstall the pedal. LEVELING ARM 1.
PARTS REMOVAL AND REPLACEMENT PEDAL ARM 1. Remove the pedal and the bottom cover. 2. Remove the step chain retainers. 3. Support the pedal arm. Unhook the pedal arm return spring from the spring hanger. Lift the step chain up and off the clutch sprocket and lower the pedal arm to the floor. 4. Remove the master link from the step chain connection point. 5. Remove the snap ring from the pedal arm mounting shaft and the leveling arm pin.
PARTS REMOVAL AND REPLACEMENT ECCENTRIC HUB ASSEMBLY 1. Remove the bottom cover. 2. Remove the Poly-V and HTD belts. 3. Loosen and remove the four nyloc nuts and bolts from the hub. Remove the assembly from the frame. 4. Reassemble in the reverse order. Ensure the belts are properly tensioned; refer to the "Poly-V and HTD belt" section. FIRST REDUCTION SHAFT ASSEMBLY 1. Remove the bottom cover. 2. Remove the drive chain. 3. Remove the eccentric shaft assembly. 4.
PARTS REMOVAL AND REPLACEMENT UPPER HANDLES (4600 PT/CL) 1. Disconnect the left and right contact heart rate cables from the back of the console. 2. Remove the two mounting screws from the top and bottom shield (see Figure 19) and remove the shields from the upper handle assembly. 3. Remove the four handrail adapter screws from the upper handle assembly. 4. Remove the upper handle assembly from the machine. The contact heart rate cables are threaded through the handrail adapter.
PARTS REMOVAL AND REPLACEMENT 5. Tilt the machine forward and use an extended socket to remove the two handrail adapter screws from the front leg of the machine. 6. Tilt the machine back into place and pull each handrail out sideways. Be aware that the handrail extrusion connects the left handrail to the right handrail, and may fall out when one side is removed. 7. Reverse the removal procedures to reinstall the handrail. ALTERNATOR 1. Remove the bottom cover.
GROUNDING INSTRUCTIONS The machine must be grounded if you are using the external power supply or the battery charger. Grounding provides the path of least resistance for the electric current, thereby reducing the risk of electric shock. The power supply or battery charger must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.
FCC COMPLIANCE This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. 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.
IMPORTANT PHONE NUMBERS If you need assistance, please have both the serial number of your machine and the date of purchase available when you contact the appropriate StairMaster® Sports/Medical Products, Inc. office listed below.
BATTERY RECYCLING CENTERS After installing a new battery, you will need to properly dispose of (recycle) your old lead-acid battery. Most federal and state regulations require lead-acid batteries be recycled. Do not throw away old batteries. Lead is a heavy metal and is toxic to living organisms. Contact the nearest Yuasa-Exide, Inc. recycling center from the list below to get information on the proper disposal of your old lead-acid battery.
BATTERY RECYCLING CENTERS ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
FIGURES Figure 10: Parts Needing Periodic Maintenance Page 66
FIGURES Figure 11: Final Assembly - Left, 4600 PT Page 67
FIGURES Figure 12: Final Assembly - Right,4600 PT Page 68
FIGURES Figure 13: Final Assembly - Left, 4600 CL Page 69
FIGURES Figure 14: Final Assembly - Right, 4600 CL Page 70
FIGURES Figure 15: Covers - 4600 PT/CL Page 71
FIGURES Figure 16: Pedal Arm Assembly & First Reduction Shaft Assembly (4600/4400 PT/CL, 4200 PT) Page 72
FIGURES Figure 17:Drive Shaft Assembly & Eccentric Hub Assembly (4600/4400 PT/CL, 4200 PT) Page 73
FIGURES Figure 18: Final Assembly - Left, 4400/4200 PT Page 74
FIGURES Figure 19: Final Assembly - Right, 4400/4200 PT Page 75
FIGURES Figure 20: Final Assembly - Left, 4400 CL Page 76
FIGURES Figure 21: Final Assembly - Right, 4400 CL Page 77
FIGURES Figure 22: Covers - 4400 PT/CL, 4200 PT Page 78
FIGURES Figure 23: Cover Removal Page 79
FIGURES Figure 24: Cover fasteners Page 80
FIGURES Figure 25: Drive Chain tensioning Page 81
FIGURES Figure 26: Belt Tension Page 82
