FREECLIMBER 4200 PT, 4400 PT/CL, AND 4600 PT/CL 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 22867-A © 2001 StairMaster Health & Fitness Products, Inc. StairMaster and FreeClimber 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® FreeClimber® 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 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. 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 The Fitness Test Programs ................................................................... 24 Understanding Submaximal Exercise Testing .................................... 24 Pretest Screening ................................................................................. 26 The StairMaster® Submaximal Fit Test ............................................... 26 The Firefighter's Stair Climb Tests ....................................................... 29 Turning on the C.P.A.T. Test .........
CONTENTS Diode Test ....................................................................................... 46 Resistor Test................................................................................... 46 4600/4400 CL: ...................................................................................... 46 Battery Test .................................................................................... 46 Alternator Test ...............................................................................
CONTENTS First Reduction Shaft Assembly .................................................................. 66 Handlebar (4400 PT/CL, 4200 PT) ............................................................... 66 Upper Handles (4600 PT/CL) ........................................................................ 67 Side Handrails (4600 PT/CL) ........................................................................ 67 Alternator .....................................................................................
CONTENTS Figure 12: Final Assembly - Left, 4600 PT ................................................... 75 Figure 13: Final Assembly - Right, 4600 PT ................................................. 76 Figure 14: Final Assembly - Left, 4600 CL ................................................... 77 Figure 15: Final Assembly - Right, 4600 CL ................................................. 78 Figure 16: Covers - 4600 PT/CL ...................................................................
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 1-800-3313578 to arrange for the return of damaged parts. 6.
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 - 4200 PT and 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® Health & Fitness 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 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. IF THE CONDITION PERSISTS, YOU SHOULD CONSULT YOUR MEDICAL DOCTOR IMMEDIATELY. 2.
BASIC OPERATING INSTRUCTIONS program starts at level three. 8. As you become comfortable with exercise motion, press [LEVEL: ∧] and [LEVEL: ∨] to adjust your climbing speed. 9. Relax and stand up straight while exercising. Use the handlebars for balance (see Figure 5). 10. 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. Rest Periods 11.
BASIC OPERATING INSTRUCTIONS Figure 5: Correct Exercise Position Head - Keep your chin parallel to the floor. Avoid staring at your feet or the computer console. This posture will also enhance your breathing. Back - Although the whole body is in a slightly forward slant, keep your back straight and avoid bending at the waist. Hips/Torso - Keep your hips directly under you with the buttocks slightly contracted. Avoid letting your hips rock from side to side with each step.
HEART RATE MONITORING HEART RATE INPUT Contact heart rate and telemetry (e.g., Polar®) heart rate signal detection is available. There is no default priority of heart rate input. If a telemetry signal is detected first, contact heart rate signals are inhibited from being detected throughout the rest of the workout session and vice-versa. There is also 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 2. There are four options to handle heart rate input signals. Press the [SELECT] key to scroll through the options until you find the one option that suits your needs. Press the [ENTER] key to select that option. “ BOTH HR ON “ - allows either telemetry or contact heart rate signals to be detected. Once the console has detected a valid input signal it will lock out the opposite type of signal for the duration of the workout session.
TELEMETRY HEART RATE “HOLD HR SENSORS” - In contact heart rate signal situations this message will come every 30 seconds to prompt the user to hold the sensors. “HR MODE DISABLED” - No heart rate signal is allowed due to the set up option that was chosen. Heart rate monitoring is not possible. TELEMETRY HEART RATE (4600/4400 PT/CL ONLY) The StairMaster® FreeClimber® 4600/4400 PT/CL features telemetry (Polar®) heart rate monitoring.
TELEMETRY HEART RATE contact heart rate signals. If you do not see a heart rate on the console, try one of the following: • • • • • • • Move closer to the console. 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.
CONTACT HEART RATE CONTACT HEART RATE The StairMaster® FreeClimber® 4600 PT/CL 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 rate is displayed on the console. Contact heart monitoring is standard on the 4600 PT/CL and optional on the 4400 PT/CL.
FREECLIMBER 4400/4600 PT/CL CONSOLE The StairMaster® FreeClimber 4400/4600 PT/CL systems 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 7).
FREECLIMBER 4400/4600 PT/CL CONSOLE 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].
FREECLIMBER 4400/4600 PT/CL CONSOLE 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. Continue to press the [SELECT] key until you reach the desired statistic.
FREECLIMBER 4400/4600 PT/CL CONSOLE 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.
FREECLIMBER 4400/4600 PT/CL 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.
FREECLIMBER 4400/4600 PT/CL CONSOLE the intensity level 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.
FREECLIMBER 4400/4600 PT/CL 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 uptake and workload. That the maximal heart rate for a given age is uniform.
FREECLIMBER 4400/4600 PT/CL 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.
FREECLIMBER 4400/4600 PT/CL 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.
FREECLIMBER 4400/4600 PT/CL 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 2nd and 3rd minutes of each stage.
FREECLIMBER 4400/4600 PT/CL CONSOLE Figure 8: StairMaster® Fitness Protocol FIT TEST PRO TO COL StairMaster CV Products First W ork Level 4 M ETs If H R < 1 0 0 If 1 0 0 < = H R < = 1 2 0 If H R > 1 2 0 S econ d W ork L evel 7 M ETs S econ d W ork L evel 6 M ETs S econ d W ork L evel 5 M ETs If H R s > 1 1 5 Third W ork Level 9 M ETs If H R s > 1 1 5 Fo urth W ork Level 11 M ETs Y Third W ork Level 8 M ETs Y If H R s > 1 1 5 Y Fo urth W ork Level 10 M ETs T e s t fa ils if 2 s ta g e s o
FREECLIMBER 4600/4400 PT/CL CONSOLE Table 2.
FREECLIMBER 4600/4400 PT/CL CONSOLE intervals at an intensity of 68 steps/min. The CPAT Stair Climb Test has a total of 10 intervals and lasts for 3 minutes, 20 seconds (including warmup). 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.
FREECLIMBER 4600/4400 PT/CL 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.
FREECLIMBER 4600/4400 PT/CL 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.
FREECLIMBER 4600/4400 PT/CL CONSOLE [SELECT] [SELECT] [SELECT] [SELECT] “CONTRAST ADJ” “MAX SPEED” - N/A“CLINICAL MODE”-N/A“SET DEFAULTS “ 5 6 7 9 Machine Status Codes [ [ [ [ [ [ [ ^][4][0] ^][4][1] ^][4][2] ^][4][3] ^][4][4] ^][4][5] ^][4][6] display machine run time in hours display number of workouts display distance traveled display software rev display machine type -N/Adisplay machine run time in hours since last cleared (used for maintenance) 1.
FREECLIMBER 4600/4400 PT/CL 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.
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 9). 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 9: 4200 PT Console Diagram TOP WINDOW The top LCD window displays information while you set up your workout.
FREECLIMBER 4200 PT CONSOLE 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. The arrow pointing to the word "Weight" will flash and the number "150" will be displayed. Use the [+ or - ARROW] to adjust it to your body weight. Press [ENTER/SELECT] when it is correct. 5.
FREECLIMBER 4200 PT CONSOLE BOTTOM WINDOW The bottom LCD window keeps track of four different statistics during your workout: the number of calories burned, the climbing speed in steps per minute, the total number of floors climbed, and the total distance covered. As the console scrolls through each statistic, an arrow on the side of the display window points to the name of what is being shown. • • • • Calories. Provides a running total of the number of calories burned during a workout. Steps/Min.
FREECLIMBER 4200 PT CONSOLE START/STOP. Press this key while the console is in the ATTRACT mode to begin the workout setup. If pressed at any time during workout setup, all entries are cleared and workout setup starts over again. If pressed during a workout, a 30-second rest period is started. If pressed during a rest period, the console returns to the ATTRACT mode.
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. Major component names and locations are shown in Figure 11.
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 11, page 74.
MAINTENANCE INSTRUCTIONS ! WARNING TO REDUCE THE POSSIBILITY OF SLIPPING, BE SURE THE PEDAL AREA IS FREE OF GREASE OR OIL. WIPE ANY EXCESS OIL OFF THE MACHINE SURFACES. 7. Remove the spring pulleys every three months. Clean the spring pulley 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.
MAINTENANCE INSTRUCTIONS Table 3: Recommended Preventive Maintenance Schedule PART RECOMENDED ACTION FREQUENCY Console Wipe Clean CLEANER LUBRICANT Daily Water N/A Clean and Inspect Daily Diluted household cleaner N/A Lubricate Monthly or after 300 hours of use N/A 30W motor oil Clean and lubricate Quarterly or after 900 hours Mild degreaser 30W motor oil Clean and lubricate Every 3 months or after 900 hours Clean, dry rag Multipurpose grease Spring Pulley Shafts Clean and lubrica
TROUBLESHOOTING GENERAL TROUBLESHOOTING GUIDELINES This troubleshooting section is organized into three basic problem sections: electrical troubleshooting, console diagnostic tests, 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 to 19 VDC. Replace the power connector if the voltage is not the same value as in step 3.
ELECTRICAL TROUBLESHOOTING • • • Place a short wire with alligator clips on the B+ terminal and the field (FLD) terminal of the alternator. Step on the machine for approximately 10 to 15 seconds. If full resistance is achieved during this time, your alternator has correct current flow. If no resistance is achieved, replace the alternator. 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.
ELECTRICAL TROUBLESHOOTING 3. Step up on the machine. With the voltmeter set to DC voltage, test for greater than 6.1 VDC in pins #1 (+) and #10 (-) in the main cable connector while stepping. Replace the main cable if the voltage reading is less than 6.1 VDC. Next, check for continuity in the main cable (see Final Assembly Figure). 4. If all voltage readings have been within the specified range and the console will not power up, the console should be replaced. Alternator Test 5.
4600/4400 PT/CL 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 additional verbiage on the display other than is listed in this manual. The FreeClimber console is used on other StairMaster® equipment.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS 1. Press [ LEVEL: ^ ], [ 6 ], [ 1 ], to start the test. 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. Serial Port Test This test verifies that the RS 232 port used for linking to external C.S.A.F.E. systems (commercial entertainment systems) is working. You must have the loop-back cable assembly (PN 040051-001) to perform this test. 1.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS 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 2,000 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.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS Contact Heart Rate Test The contact heart rate system is made up of the console and the contact heart rate sensor handles. Remember that even when operating properly, the contact Heart Rate system will not work for everyone. If you suspect you have a problem with your system, have someone else try it before performing the following troubleshooting steps: 1.
4600/4400 PT/CL CONSOLE DIAGNOSTIC TESTS 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 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.
MECHANICAL TROUBLESHOOTING If you hear a grinding or clicking noise, 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 • Do not reinstall the Poly-V belt if performing step #4. Plug in the connector at position J4 or reconnect the DC power cable, as applicable. 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.
MECHANICAL TROUBLESHOOTING • Clean all corrosion off the pedal arm shaft and leveling arm shaft and bushings. Wipe the shafts with an oil-dampened cloth before reassembling. DO NOT SAND THE PEDAL ARM SHAFT OR LEVELING ARM SHAFT. 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.
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 3. 4600 PT/CL: Use the fastener removal tool to release the cover fasteners and separate the top covers. 4. 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 11). 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 11). ! 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 27). 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 18). 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 17). ! 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 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.
APPENDICES 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 12421 Willows Road NE, Suite 100 Kirkland, WA 98034 (800) 635-2936 or (425) 823-1825 FAX: (425) 823-9490 www.stairmaster.
APPENDICES BATTERY RECYCLING After installing a new battery, 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. 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.
APPENDICES ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
APPENDICES Figure 11: Parts Needing Periodic Maintenance Page 74
APPENDICES Figure 12: Final Assembly - Left, 4600 PT Page 75
APPENDICES Figure 13: Final Assembly - Right,4600 PT Page 76
APPENDICES Figure 14: Final Assembly - Left, 4600 CL Page 77
APPENDICES Figure 15: Final Assembly - Right, 4600 CL Page 78
APPENDICES Figure 16: Covers - 4600 PT/CL Page 79
APPENDICES Figure 17: Pedal Arm Assembly & First Reduction Shaft Assembly (4600/4400 PT/CL, 4200 PT) Page 80
APPENDICES Figure 18:Drive Shaft Assembly & Eccentric Hub Assembly (4600/4400 PT/CL, 4200 PT) Page 81
APPENDICES Figure 19: Final Assembly - Left, 4400/4200 PT Page 82
APPENDICES Figure 20: Final Assembly - Right, 4400/4200 PT Page 83
APPENDICES Figure 21: Final Assembly - Left, 4400 CL Page 84
APPENDICES Figure 22: Final Assembly - Right, 4400 CL Page 85
APPENDICES Figure 23: Covers - 4400 PT/CL, 4200 PT Page 86
APPENDICES Figure 24: Cover Removal Page 87
APPENDICES Figure 25: Cover fasteners Page 88
APPENDICES Figure 26: Drive Chain tensioning Page 89
APPENDICES Figure 27: Belt Tension Page 90
