STEPMILL 7000 ® OWNER’S MANUAL
Printed in the United States. ® © 2001 StairMaster Health & Fitness 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 22869 - A © 2001 StairMaster Health & Fitness Products, Inc. StairMaster and Stepmill are registered trademarks or trademarks of StairMaster Health & Fitness Products, Inc. in the United States and/or other countries.
WARRANTY This is to certify that the StairMaster® Stepmill® 7000 PT exercise system is warranted by StairMaster Health & Fitness 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 The StairMaster® Stepmill® 7000 PT exercise system is a safe, functional, and effective exercise modality for developing aerobic fitness and increasing the strength of the major muscle groups of the lower body. It is designed for use by individuals of all ages and fitness levels. Your purchase of this machine is a positive affirmation of your commitment to use the best available methods for enhancing your functional fitness capabilities.
CONTENTS SAFETY GUIDELINES ......................................................................................... 1 INSTALLATION INSTRUCTIONS ........................................................................ 3 BASIC OPERATING INSTRUCTIONS ................................................................ 6 General Guidelines for Safe Operation ........................................................... 6 Your First Workout on the StairMaster® Stepmill® 7000 PT Exercise System .......................
CONTENTS Turning the CPAT Stair Climb Test on ...................................................... 26 Turning the NYCFD Stair Climb Test on ................................................... 26 Console Codes ............................................................................................. 27 MAINTENANCE INSTRUCTIONS ................................................................... 31 Helpful Hints ..............................................................................................
CONTENTS Step Assembly .............................................................................................. 54 Step Chain Assembly ................................................................................... 55 Upper (and Lower) Sprocket Assembly ....................................................... 57 Cable Assembly ............................................................................................ 59 Transmission Assembly ........................................................
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® Health & Fitness Products, Inc. 5. Do not use the external power supply if it has a damaged cord or plug, or if it is not working properly, if it has been dropped or damaged, or dropped into water. Contact our Customer Service Department at 1-800-3313571 to arrange for the return of damaged parts. 6.
INSTALLATION INSTRUCTIONS Before leaving the manufacturing facility in Tulsa, Oklahoma, your StairMaster® Stepmill® 7000 PT exercise system was thoroughly inspected and tested for proper operation. To minimize shipping damage, careful attention was given to making your machine ready for shipment. The dimensions of the machine are listed in Table 1. 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. Table 1.
INSTALLATION INSTRUCTIONS 3. Remove the clevis pin from each wheel (See Drawing Below) and remove the wheels from the frame. Rivnut 4 X 21767 Clevis Pin 2 X 24439 Cotter Pin 2 X 20047 Outside of Machine Nut 4 X 22154 Leg Leveler 4 X 20017 Transport Wheel 2 x 20036 4. Help your assistant lower the machine to the floor. Install and adjust the leg levelers as necessary to level the machine (see Above). 5.
INSTALLATION INSTRUCTIONS ! 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. 9. Connect the AC power cord to the AC wall outlet. Refer to the “Grounding Instructions” section of the Manual if the AC wall outlet does not accept a three-prong plug. 10. Watch the console.
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® STEPMILL® 7000 PT EXERCISE SYSTEM Basic Instructions for First-Time Users 1. Warm up with light calisthenics and easy stretching exercises for at least five minutes before beginning your exercise program. ! WARNING IF AT ANY TIME DURING YOUR WORKOUT YOU FEEL CHEST PAIN, EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF BREATH, STOP EXERCISING IMMEDIATELY.
BASIC OPERATING INSTRUCTIONS 8. Relax as much as possible while exercising and maintain an erect posture. Use the handrails for balance. Don’t lock your elbows or lean on the console. Supporting your weight will reduce the exercise intensity and the console will overestimate the number of calories burned. 9. Select a speed (or intensity level) that allows you to step towards the top of the staircase. Faster is not always better. Exercise at a level that is consistent with your fitness level.
BASIC OPERATING INSTRUCTIONS Figure 1: Correct Exercise Position Chest/Shoulders - Keep your shoulders square and centered over your hips with your chest lifted. Hands - Rest your hands lightly on the side rails or front handlebars. Excessive leaning on the side rails can reduce calorie burn by up to 20%. Elbows - Keep both elbows slightly bent. If you have good balance and want to burn more calories, you can pump your arms back and forth as if you were running.
HEART RATE MONITORING HEART RATE INPUT The 7000 PT console uses telemetry (e.g., Polar®) heart rate signal detection. Ensure that your console is set up for telemetry signal detection only. There is a short “lock out” period at the beginning of each workout session during which the console first detects a signal and then validates the signal type.
HEART RATE MONITORING “TELEMETRY ONLY“ - locks out contact heart rate signals and will only detect telemetry signals. Set your console to this default. “BOTH HR OFF“ - turns off the ability to detect any signal at all. Used in rare situations where there is excessive interference with the heart rate signals. This option turns off disables the Constant HR program and the Fitness Test program.
TELEMETRY HEART RATE TELEMETRY HEART RATE The StairMaster® Stepmill® 7000 PT features telemetry (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 monitoring function is activated as soon as you strap on the chest belt and step within range of the receiver in the machine. Two electrodes on the underside of the chest belt sense the heart rate signal and send it to the receiver.
TELEMETRY HEART RATE • • • • • • Tighten the elastic part of the chest belt. Adjust the belt higher or lower on your chest. Remoisten the electrodes. Test your chest strap with a machine that you know is working, or with a heart rate watch that you know is working. If possible, replace or exchange your console with a console (from the same type of machine) that you know is working and retest the machine. Visually check that the heart rate receiver is positioned correctly in the neck cover.
7000 PT CONSOLE The StairMaster® Stepmill® 7000 PT exercise system console is divided into seven sections: the display window, the workout options, the numeric keypad, the entertainment keypad, the workout statistics, the stop key, and the intensity level keys (see Figure 3).
7000 PT CONSOLE THE NUMERIC KEYPAD The numeric keypad is located on the right side of the console. Before the exercise program begins, the numbers are used to enter data in response to the console prompts. • Enter - Confirms workout selections and stores the information used by the console to calculate workout statistics. • Clear - Erases information from the console memory if pressed before [ENTER].
7000 PT CONSOLE THE WORKOUT STATISTICS During the exercise program, the Stats keys are used to track workout statistics which are then shown in the display window. Pressing the [SELECT] key turns off the scanning feature and shows the statistic of choice in the display window.
7000 PT CONSOLE THE EXERCISE PROGRAM KEYPAD The exercise keypad is located below the display and to the left of the function keypad. While the console is in the “SELECT WORKOUT” mode, press one of the exercise program keys to preview the desired workout. There are six workout programs with the following standard defaults (pressing [ENTER] without inputting data first will prompt the console to enter these values): • • • • Weight - 175 lbs.
7000 PT CONSOLE on the selected intensity level, with 2 levels equating to one vertical bar. The Fat Burner Program The Fat Burner program is a 60-interval workout designed for people just starting a weight control program. The relative intensity level is indicated on the profile and any changes in the intensity level will continue for the remainder of the program. The Aerobic Training Program The Aerobic Training program is a 60-interval workout designed to increase aerobic capacity.
7000 PT CONSOLE during an EXERCISE interval. The intensity level shown during an EXERCISE interval is indicative of your current speed. However, the current speed during a REST interval is equal to a scaled percentage of the displayed intensity level. Note that the program profile does not change at any time during the workout session.
7000 PT CONSOLE The Fitness Test Programs Understanding Submaximal Exercise Testing Before using the StairMaster FreeClimber for submaximal exercise testing, it should be noted that all submaximal fitness tests make several assumptions: • • • • That a steady-state heart rate is obtained for each exercise workload. That a linear relationship exists between heart rate, oxygen up take and workload. That the maximal heart rate for a given age is uniform.
7000 PT CONSOLE 150, external factors no longer influence heart rate, and a linear relationship exists. As the heart rate rises above 150, the heart rate-oxygen uptake relationship becomes curvilinear. The third assumption involves maximal heart rate. Maximal heart rate is the greatest heart rate that can be measured when an individual is exercising to the point of volitional fatigue (i.e., exhaustion) during a graded exercise test.
7000 PT CONSOLE submaximal exercise tests and that person’s heart rate response to a fixed workload is found to decrease over time, it is reasonably safe to conclude that the individual has made improvements in aerobic (cardiorespiratory) fitness, irrespective of the accuracy of the VO2 max prediction.
7000 PT CONSOLE state heart rate of the subject to 110 to 150 beats/min for two consecutive stages. It is important to remember that two consecutive heart rate measurements must be obtained in the 110 to 150 beats/min range to predict VO2max. The test typically lasts from 9 to 15 minutes. In the StairMaster protocol, each work rate is performed for 3 minutes, with heart rates recorded during the final 4 seconds of the second and third minutes of each stage.
7000 PT CONSOLE Figure 4: StairMaster® Fitness Protocol FIT TEST PROTOCOL StairMaster CV Products First Work Level 4 METs If HR < 100 If 100 <= HR <= 120 If HR > 120 Second Work Level 7 METs Second Work Level 6 METs Second Work Level 5 METs If HRs >115 Third Work Level 9 METs If HRs >115 Fourth Work Level 11 METs Y Third Work Level 8 METs Y If HRs >115 Y Fourth Work Level 10 METs Test fails if 2 stages of at least 115 bpm are not obtained Test Complete - Display Results - Page 24
7000 PT CONSOLE Table 2.
7000 PT CONSOLE intervals at intensity of 68 steps/min. The CPAT Stair Climb Test has a total of ten intervals and lasts for three minutes, twenty seconds (including warm-up). Turning on the CPAT Stair Climb Test 1. Press [∧], [9], [1], [ENTER], on the console keypad. Make sure to press in the middle of each key and be aware that the corresponding numbers will not show in the console display. 2. The console will prompt you to “BEGIN FIT TEST.” The test can be stopped at any time by pressing [STOP].
7000 PT CONSOLE CONSOLE CODES There are three groups of console codes which are differentiated according to function. The first group of codes are customization codes and are used to set defaults such as units, language, heart rate input type, etc. The second group of codes are machine status codes and are used to track hours and other general usage patterns for maintenance purposes. The third group of codes are diagnostic codes and are used for troubleshooting.
7000 PT CONSOLE 2. Change the units to either Metric or USA units by pressing [LEVEL: ^], [3], [1], [ENTER]. The console will display the current units - either “USA UNITS” or “METRIC UNITS.” Use the [SELECT] key to change option, and then press [ENTER]. 3. Choose the desired heart rate input preference by pressing [LEVEL: ^], [3], [2]. The console will then display “HR INPUTS.” Press [ENTER]. The console will then display the current hear rate input selection.
7000 PT CONSOLE [SELECT] “CONTRAST ADJ” [SELECT] “MAX SPEED” - N/A[SELECT] “CLINICAL MODE”-N/A[SELECT] “SET DEFAULTS “ 5 6 7 9 Machine Status Codes [ [ [ [ [ [ [ ^ ] [ 4 ] [ 0 ] display machine run time in hours ^ ] [ 4 ] [ 1 ] display number of workouts ^ ] [ 4 ] [ 2 ] display distance traveled ^ ] [ 4 ] [ 3 ] display software rev ^ ] [ 4 ] [ 4 ] display machine type ^ ] [ 4 ] [ 5 ] -N/A^ ] [ 4 ] [ 6 ] display machine run time in hours since last cleared (used for maintenance) 1.
7000 PT CONSOLE Quick Scan Programming You can quickly access any of the custom menus by pressing [LEVEL: ^], [4], [ENTER]. The console will then display “MACHINE STATUS.
MAINTENANCE INSTRUCTIONS HELPFUL HINTS Read all maintenance instructions thoroughly before beginning work. In some cases, an assistant is required to perform the necessary tasks. The safety level given by the design of this equipment can only be maintained when the equipment is regularly examined for damage and wear. Inoperable components shall be replaced immediately or the equipment shall be put out of use until it is repaired.
MAINTENANCE INSTRUCTIONS 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. Refer to the “Installation Instructions” section of this Manual for details. PREVENTIVE MAINTENANCE The procedures for performing the recommended preventive maintenance are summarized in Table 3.
MAINTENANCE INSTRUCTIONS 5. Clean the step hinges carefully. Perspiration tends to accumulate in the hinges, and this can lead to eventual corrosion. 6. Inspect the Poly-V belt for excessive wear during the weekly cleaning. Adjust the belt tension if necessary. Lubrication The StairMaster® Stepmill® 7000 PT exercise system has six components that require periodic lubrication: the drive chain, the two step chains, the two bearing plates and the step hinges. These parts are shown in the figure below.
MAINTENANCE INSTRUCTIONS 2. Lubricate the chains monthly with 30W motor oil. Drip the oil onto the chain plates and rollers. Let the oil soak in for a few minutes and then remove any excess oil with a dry rag. 3. Remove the chains every three months to thoroughly clean and lubricate them. Use a mild degreaser and a stiff brush to remove dirt and corrosion from the chain. Read the instructions on the degreaser container before using. 4.
MAINTENANCE INSTRUCTIONS Table 3.
TROUBLESHOOTING GENERAL TROUBLESHOOTING GUIDELINES This section outlines several tests to systematically identify and isolate the cause of problems in the electrical system and the drive train. This troubleshooting section is organized into four basic problem sections: Electrical System, Console Diagnostics, Speed Control, and the Drive Train. The first step is to identify the problem. Once you have identified the problem, perform all the tests in exactly the same order as written.
TROUBLESHOOTING THE ELECTRICAL SYSTEM 2. Verify that the AC wall outlet is supplying the correct power in one of two ways: a) Use a voltmeter to verify that the AC line voltage is between 108 and 130 VAC (or between 208 and 240 VAC, if applicable) at the AC wall outlet; or b) Plug in an alternate AC-powered device (a lamp, for example). If the AC wall outlet is supplying the correct power, proceed to step #3.
TROUBLESHOOTING THE ELECTRICAL SYSTEM assembly circuit board (refer to Wiring Diagram 2). Use a DC voltmeter to measure the VDC at the power connector. Pin #1 is negative and Pin#10 is positive. The reading should be between 12 and 19 VDC. If you are not getting power to the connector, replace the power connector assembly and retest. 5. b. If you are getting the correct voltage at the power connector, reconnect it to the J2 position on the relay assembly circuit board.
CONSOLE DIAGNOSTIC TESTS The following tests are performed while the console is in the “SELECT WORKOUT” mode. If the console fails any test, the console should be replaced or exchanged. To return to the “SELECT WORKOUT” mode, press either [CLEAR] or [START/STOP] while in the DIAGNOSTIC mode. Please note that there may be addition verbiage on the display other than is listed in this manual. The Stepmill® 7000 PT console is used on other StairMaster® equipment.
CONSOLE DIAGNOSTIC TESTS 2. Firmly press each button except [CLEAR]. The name of the key will be shown in the display window. Press [CLEAR] to end the test. The Serial Port Test This test verifies that the RS 232 port used for linking to commercial entertainment systems is working. You must have the loop-back cable assembly, pn 040051-001 to perform this test. 1. Insert the loop-back cable assembly into the RS 232 port on the back of the console. 2.
CONSOLE DIAGNOSTIC TESTS The Tach Test If you do not have resistance, perform the tach test. The tach test will tell you the tach signal, in revolutions per minute (RPMs), picked up by the console. 1. Press [ LEVEL: ^ ], [ 6 ], [ 6 ], [ENTER]. The console will display “TAR TACH ACT”. The target tach speed of 2000 RPMs will be shown in the upper left corner of the display window. The actual tach picked up by the console will be shown in the upper right corner of the display window. 2.
CONSOLE DIAGNOSTIC TESTS The Telemetry (Polar®) Heart Rate Test The telemetry heart rate system is made up of the console, the heart rate receiver, and the chest strap (available separately). You can test each component by performing the following steps: 1. You will need to put a chest strap on in order to test the telemetry heart rate. Before you put on the chest strap, wet the two contact patches. Secure the chest strap as high under your pectoral muscles (chest) as is comfortable.
SPEED CONTROL PROBLEMS If you have problems with erratic speed control while operating the machine, the cause may be either electrical or mechanical in nature. You will have to remove the side covers to conduct most of these tests. A. Perform a visual check of the machine. Check the following things first: 1. Inspect the Poly- V belt for proper tension and excessive wear. A loose belt will cause excessive noise and wear. The machine will run sluggishly if the belt is too tight. 2.
SPEED CONTROL PROBLEMS 4. Replace or exchange the console with another console you know is good and retest the machine. B. Check the relay assembly circuit board while the console displays "SELECT WORKOUT." You will need an assistant to complete the test of the relay assembly circuit board. 1. Remove the right side cover. Locate the relay assembly circuit board located just inside the frame, midway between the top and bottom steps (refer to Wiring Diagram).
SPEED CONTROL PROBLEMS to Figure on page. 34). The relay indicator should light up. If it does, go to step #4. If the relay indicator does not light up, the relay assembly circuit board must be replaced. Replace the relay assembly circuit board and retest the machine. 4. You must check the cable assembly for continuity if the relay indicator lit up when you jumped tabs #1 and #5. a. Unplug the main cable from the position labeled J1 on the relay assembly circuit board.
SPEED CONTROL PROBLEMS a. Unplug the connector at position J1 on the relay assembly circuit board. Disconnect the console cable from the back of the console. Set your multimeter to the continuity check mode; on most meters this will be the resistance or ohms setting. b. Place one lead of the multimeter on pin #2 at the console connector end of the console cable. Place the other lead on pin #2 at the end of the main cable you disconnected from the relay assembly circuit board.
LOAD RESISTOR TEST The alternators are heavy-duty models designed to withstand the rigors of commercial use. One possible reason for repeated failure is an inoperable load resistor. To test the load resistor: 1. Unplug the AC power cord from the AC wall outlet. 2. Locate the load resistor mounted to the relay board assembly just under the staircase. 3. Disconnect one black wire from the resistor (See Drawing Below). 4. Set your multimeter for R x 1 or the lowest available resistance range.
TROUBLESHOOTING THE DRIVE TRAIN If you hear a grinding or clicking noise, or experience excessive vibration during exercise, or if the steps 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 of this Manual for all disassembly and assembly instructions. 1.
TROUBLESHOOTING THE DRIVE TRAIN 3. Check the condition of the alternator. a. Unplug the alternator from the relay board and remove the Poly-V belt. b. Spin the alternator pulley with your fingers. It should spin freely and remain spinning for at least one and one-half revolutions. If it does not spin as it should, the bearings may be bad and the alternator should be replaced. c.
TROUBLESHOOTING THE DRIVE TRAIN 7. Check the condition of the upper and lower sprocket assemblies. Replace the sprocket assembly if it is worn excessively, has broken teeth, or if it is bent. 8. Check the alignment of the upper and the lower sprocket assemblies. The outside face of the upper and lower sprockets should be 1-11/16" (4.3 cm) from the outside edge of the left frame rail.
PARTS REMOVAL AND REPLACEMENT COVERS ! WARNING TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE THE SIDE COVERS ARE REMOVED. DO NOT ROTATE THE STAIRS WHILE ANYONE'S HANDS ARE INSIDE THE MACHINE. There are five covers on the machine: two side covers, a back cover, a bottom cover, and a top cover. The side covers overlap the top cover. The side covers must be removed before the top cover and/or the bottom cover can be removed.
PARTS REMOVAL AND REPLACEMENT Back Cover 1. Remove the 8 fasteners and lift the back cover away from the frame. 2. Align the holes in the frame and the back cover. Secure the back cover with the 8 fasteners. Bottom Cover 1. Remove both side covers to gain access to the bottom cover fasteners. 2. Disconnect the DC power cable. 3. Remove the six fasteners and remove the bottom cover from the frame. 4. Reinstall the bottom cover, then the two side covers. Remember to connect the DC power cable. CONSOLE 1.
PARTS REMOVAL AND REPLACEMENT POLY-V BELT ! WARNING THE POLY-V BELT MUST BE ADJUSTED SO THAT THE CENTER OF EITHER SIDE CAN BE DEFLECTED 1/10" (0.3 CM) FROM ITS CENTER LINE WITH FINGERTIP PRESSURE. A TIGHT BELT WILL CAUSE SLOW AND SLUGGISH OPERATION; A LOOSE BELT WILL CAUSE EXCESSIVE NOISE AND BELT WEAR. 1. Remove the left side cover. 2. Loosen the adjustment bolt that mounts the alternator to the slotted alternator brace then loosen the pivot nut. 3. Pivot the alternator forward to loosen the belt.
PARTS REMOVAL AND REPLACEMENT 3. Push up on the idler arm with one hand to relieve the tension on the drive chain (See Drawing Below). Remove the master link from one end of the drive chain and remove the drive chain from the sprockets. 4. Install the new drive chain by reversing the steps. STEP ASSEMBLY 1. Remove the right and the left side covers. 2. Rotate the stairs until the step you want to remove is positioned in the middle of the staircase. Step Tread 3.
PARTS REMOVAL AND REPLACEMENT Be careful to not lose the washer located between the step and the modified link. Note: Each step assembly weighs approximately 15 lbs. Be aware of finger placement when removing the step assembly. 6. Reinstall the step by reversing the procedures. STEP CHAIN ASSEMBLY 1. Remove the right and the left side covers. 2. Rotate the stairs to position the step chain master link on the lower span of the chain. It may be necessary to reduce the chain tension to remove the master link.
PARTS REMOVAL AND REPLACEMENT • Loosen the nuts on the pillow block bearing housing. • Loosen the bearing adjustment set screw until the chain tension level is relieved to a point where the master link may be disconnected. 3. Remove the master link. 4. Using the old master link, connect the new chain assembly to the lower half of the old chain assembly. 5. Remove the nut from the step shaft above the master link.
PARTS REMOVAL AND REPLACEMENT UPPER (AND LOWER) SPROCKET ASSEMBLY 1. Remove the right and left side covers. 2. Remove all of the steps. 3. Remove the drive chain if you are removing the upper sprocket assembly. 4. Count and write down the number of exposed threads on the bearing adjuster set screws on both sides of the machine for a reference when you reassemble the parts (See Drawing Below). 5. Remove the right and left step chain assemblies. 6.
PARTS REMOVAL AND REPLACEMENT 7. Have an assistant support the sprocket assembly. Loosen and remove the nuts on the pillow block bearing housing. 8. Remove the sprocket assembly from the frame. 9. Loosen the two set screws on both of the pillow block bearing collars and remove the pillow block bearings from the sprocket axle. 10. To reinstall the sprocket assembly: • Slide the pillow block bearings on both ends of the sprocket axle. Do not tighten the set screw on the pillow block bearing collars yet.
PARTS REMOVAL AND REPLACEMENT 11. Complete the reassembly of the machine by performing steps 1- 4 in reverse order. CABLE ASSEMBLY 1. Remove the right side cover. 2. Remove the console and unplug the console cable from the back of the console (See Drawing Below). Unplug the plastic connectors at the console cable/main cable junction. 3. Hold the console connector and pull the console cable up and out of the handrails. 4.
PARTS REMOVAL AND REPLACEMENT 6. Unplug the white plastic connector labeled J1 on the relay assembly circuit board. 7. Cut the four tyraps on the vertical support. 8. Remove the main cable from the frame. 9. To reinstall, place the main cable into the wire saddles. Reattach the cable to the vertical support with four tyraps. 10. Plug the white plastic connector of the main cable into the relay assembly circuit board at the spot labeled J1. 11. Plug the console cable into the back of the console.
PARTS REMOVAL AND REPLACEMENT 7. Support the transmission while loosening and removing the four transmission mounting bolts. Remove the transmission and rubber pad from the frame (See Drawing Below). 8. Reinstall the transmission by reversing the removal procedures. 9. Ensure the Poly-V belt is tensioned according to the procedures outlined in the “Poly-V Belt” section of this Manual. ALTERNATOR ASSEMBLY 1. Remove the right and left side covers. 2. Remove the step positioned in the middle of the staircase.
PARTS REMOVAL AND REPLACEMENT 4. Remove the Poly-V belt. Inspect the belt for wear. Replace the belt if it is cracked, worn, torn, or cut. 5. Remove the alternator adjustment bolt (See Drawing on Pg. 51). 6. Remove the nut, bolt and mounting hardware from the alternator bracket. Remove the alternator from the frame. 7. Reinstall the alternator by reversing the removal procedures. Be sure to verify the wiring connections. 8. Ensure the Poly-V belt is tensioned correctly (See Drawing Below).
PARTS REMOVAL AND REPLACEMENT 5. Unplug the power connector from the J2 position on the relay circuit board. 6. Loosen and remove the four mounting bolts and remove the relay/resistor assembly from the frame. 7. Reinstall the relay/resistor assembly in the reverse order. Verify the wiring connections before attaching the side cover.
GROUNDING INSTRUCTIONS The machine must be grounded. If it should malfunction or break down, grounding provides the path of least resistance for the electric current, thereby reducing the risk of electric shock. This machine is equipped with a cord having an equipment-grounding conductor and a grounding plug that looks like the plug illustrated in sketch A in the Drawing below. International machines may vary.
FCC COMPLIANCE This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, 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® Health & Fitness Products, Inc. office listed below. OFFICES IN THE UNITED STATES CORPORATE HEADQUARTERS CUSTOMER SERVICE 12421 Willows Road NE, Suite 100 12421 Willows Road NE, Suite 100 Kirkland, WA 98034 Kirkland, WA 98034 (800) 635-2936 or (425) 823-1825 (800) 331-3578 FAX: (425) 823-9490 FAX: (425) 814-0601 www.stairmaster.
Left Handrail 22947-03 Right Handrail 22946-03 Top Cover 22555 8 X 22086 Caution Decal 7 X 24757 Distribution Decal Serial Number Decal Compliance Decal Right Side Cover 22547 23 X 24757 36 X 22086 Left Side Cover 22544 Inside Panel Right - 24638 Left - 24639 Transport Wheel Assembly 2 X 10262 FIGURES Page 67 Bottom Panel 22563 Figure 6: Side Cover and Handrail Assemblies Back Panel 21304
FIGURES Figure 7: Cover Fasteners Page 68
24 X 21363 Console Step Tread 8 X 21398 Step Assembly (w/Tread) 8 X 21396 Modified Link (22063) (23082) (22128) 80 X 20528 (22128) Modified Link Detail A Step Shaft Bearing 16 X 23082 (22128) 32 X 22128 Step Shaft Nut 16 X 22063 Step Shaft 8 X 20762 Figure 8: Step Assembly 80 X 20508 See Detail A FIGURES Page 69
(22071) (22072) 4 X 10037 6 X 22032 (22039) 4 X 22039 2X 22072 8 X 22029 Chain Section, #40 5.5” 4 X 20532 Lower Sprocket Assembly 10205-03 Chain Section, #40 11.
2 X 22191 4 X 22028 4 X 22027 22163 22029 (22191) 22030 2 X 22191 22433 20114 Transmission Assembly 23591 (22037) Alternator Transmission Pulley 20205 Transmission 24662 20001 (22036) 20202 22042 20693 4 X 22036 20007 (22036) (22038) 22043 Poly-V Pulley 22983 (22036) 21247 (22036) 4 X 22038 (22038) Frame 23427 10860 10059 (22435) 22075 2 X 22435 2 X 22037 (22038) 22146 2 X 22026 2 X 22164 20547 (22164) 22139 Transmission Assembly Mounting to the Frame Upper Sprocket Assembly 23424-03 Drive Chain 2325
FIGURES Page 72 Console 2 X 21363 Console Cable 21416 4 X 22213 2 X 24643 2 X 22937 4 X 22323 Fastener, Hook 22938 Fastener, Loop 22939 10794-03 Grommet 15034 4 X 22323 4 x 22213 4 x 24643 2 X 24640 Tywrap 25233 4 X 22028 Cut-Away View of Polar Receiver W-4 AC Tap 5 X 23792 4 X 22036 (22933) Grommet 24663 Polar Cable Assy, 12” 26143 Heart Rate Cap 21765 Receiver, Polar® Plug-in 25165 W-5 Positive Output W-6 Ground W-5 W-4 W-3 W-2 W-1 Main Cable 21769 4 X 20473 Relay Board W-2 W-6 W-1
FIGURES Figure 12: Relay Board Page 73
