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Service Manual

1. YN Spacer 18021 t5 Console Bracket Premi Left 18006 03 9 18077 Upper Handles 2 x18000 18022 03 21449 Resi Resistor to Handrail Assembly 27 Right 18017 2 Groundl Black Black See Detail H Resistor to Main Cable to Ground 2 7 1 2X22075 Bracket C 24666 03 za Link 21590 03 21829 Black oa 4 22047 Power Connector 4 X22026 to Groundl 4 X22036 Spring Pulley 2 X21519 Washer 2 X 22142 White Snap Ring 2 X 21462 Main Cable to 2 X24164 Power Connector 2X21774 LULA 2 X 22326 Main Cable 21417 1d 009p quBra jq ossy jeu 21 2 64 5394 94 69 22026 22175 Main Cable 21415 Handrail Assembly Loft 18016 03 22246 Battery Brace Pulley 21468 21587 mt Speed Sensor Disk Altemator 22517 Section B B Green Power Connector 13597 tDchassisglOund White Power Co ector to PCB NU EU ENR 5 f iiie NK e F 2 x 20768 F 4x22663 2 20157 Section C G 2 22075 12 009 491 quiessy jeury 252614 S34uf213 0 Upper Handle 180201 Spacer 18021 Console Bracket Console Brac Right 18007 03 Left 18006 03 NC Handrail Assembly Right 18017 03 lack Main Cable21415 Detail H ig PCB White B4 to PCB gt 27 Black EN 9 AEX 2 lt S PSSN QAUM ate e 4122098 2 214
2. FreeClimber Systems CLIMBING 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 StairMaster PIN 22569 E 1997 StairMaster Sports Medical Products Inc StairMaster and FreeClimber registered trademarks or trademarks of StairMaster Sports Medical Products Inc in the United States and or other countries All other trademarks are trademarks of their respective companies Page iii UAR NOSE 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 The StairMaster name on your equipment reinforces your club s reputa tion for quality and effectiveness NATIONAL SALES SUPPORT Stai rMaster is one of the few organizations that ma inta ins its own fully staffed national sales organization These individuals wil bend over backwards
3. 12 2164 SANIT 9 1 co Console Assembly 24323 Fastener Loo 4577 4 amp HI HL Fastener Hook Neck Cover ToRecove Right 18024 06 22938 Left 18025 06 9 Lower Right VV Cover score 4200 272498106 824757 5 5 Lower Left 5 Cover sS 4400 PT 27068 06 y 4400 CL 27056 06 4200 PT 24982 06 FIGURES Figure 23 Cover Removal 1 Remove 4 fasteners and slide mid cover back and separate neck covers 4400 4200 PT CL Neck covers slide up in one piece m Bottom cover 3 Remove 2 fasteners carefully spread the bottom covers apart and separate the bottom cover from the frame Page 79 FIGURES Figure 24 Cover fasteners Cover Fastener Cover eS Frame Tube sn Fastener Removal Tool Fastener Removal Tool 23853 Page 80 FIGURES Page 81 FIGURES Figure 26 Belt Tension Eccentric Hub remove bolts and 600 to tension the HTD bel HTD Belt 21529 Poly V Belt 21518 Poly V Pulley Page 82
4. 4 2 4 ENTER Press the code number for the desired language see Table 4 and then press ENTER 2 To change the console to metric units press INCREASE 9 7 6 0 ENTER and then 1 Press ARROW 9 7 6 0 ENTER and the 0 to change back to English units CONSOLE CODES The console codes and the corresponding functions are listed in Table 4 Without standing on the pedals press INCREASE before pressing the code s number keys and then press ENTER Some codes like the one to change the language ofthe console prompts have options that require you to press a second code number and then ENTER to select that option Page 26 SAIN x BUG 2 FREECLIMBER 4600 4400 PI CL CONSOLE Table 4 Console Codes 105 Clears the custom programmed scrolling message 107 Activates the Diagnostic mode 0 Display test 1 Speaker test 2 Keypad test 3 Speed test 4 Software revision test 108 Heart rate software test 1650 Programs a custom workout 2121 Tums on the custom scrolling message 2123 Tums off the custom scrolling message 7424 Changes the language of the console prompts 7607 Tums on the custom message option 99 Text bar scrolling message editing function 7703 Displays machine usage information 7704 Allows you to turn the console speaker on or off 0 Tums the speaker on 1 Tums the speaker off 7705 Allows you to turn the Heart Rate featur
5. 0 43 66 K 21 4 67 L 22 N 45 68 EDITING THE SCROLLING MESSAGE 1 Whilethe console is in the ATTRACT mode press INCREASE 7 6 OJ 7 ENTER to display the first character of the message onto the text bar 2 Press INCREASE or DECREASE to scroll through the message cter 3 Press CLEAR to delete the last character displayed on the text bar Press 0 to end the editing process Page 25 FREECLIMBER 4600 4400 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 ATIRACT mode T Press INCREASE 2 1 2 3 ENTER to display the default scrolling message on the text bar 8 Press INCREASE 2 1 2 1 ENTER to display your custom scrolling message on the text bar CHANGING THE CONSOLE UNITS AND PROMPT LANGUAGE The console is set at the manufacturing facility to English language prompts and English units While the console is in the ATTRACT mode you can set the console for foreign language prompts or metric units 1 To change the prompt language press INCREASE 7
6. All LEOs in the console display will flash on and off as a block 3 Press CLEAR to end the test Speaker Test Use this test to make sure the console speaker is fully operational The speaker will ascend and then descend through the musical scale 1 From the DIAGNOSTIC mode press 1 to start the test 2 Press ENTER to pause the test Press CLEAR to end the test Keypad Test Perform this test if you are having trouble entering data into the console If you cannot enter the DIAGNOSTIC code due to an inoperable keypad replace the console 1 From the DIAGNOSTIC mode press 2 to start the test 2 The display LEOs will light up an L shaped formation representing the keypad matrix Pressing a button on either the exercise program Page 41 4600 4400 PTICL CONSOLE DIAG 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 You will need to briefly exercise on the machine for this test 1 From the DIAGNOSTIC mode press 3 to start the test 2 The console will be set at a certain speed The alternator spee
7. CL 4200 PI Kneel in front of the machine facing the cover seam Push in and hold both sides of the lower cover to disengage the locking tabs at the joint between the upper and lower covers Use your hands to push up the top cover and separate the top cover from the bottom cover 4600 PI CL Remove the cover fasteners and separate the left and right top cover from each other Pull out and forward on the lower cover to remove it from the frame Reinstall the covers in reverse order Ensure the top cover grommet is correctly installed at the base of the handlebar Page 49 PARTS REMOVAL AND REPLAC CONSOLE EMEN 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 Pivot up or down 2 Pivot the console up or down to adjust the console to desired viewing angle and then tighten the wing nut POLV V AND HTD BELT THE BELTS MUST BE PROPERLY TENSIONED A BELT THAT IS TOO TIGHT WILL CAUSE SLOW AND SLUGGISH OPERATION A BELT THAT IS TOO LOOSE WILL CAUSE EXCESSIVE NOISE AN DBELT WEAR 1 Remove the bottom cover 2 Loosen the adjustment bolt that mounts the alternator to the slotted alternator brace and the pivot adjusting
8. CONSOLE Top Window Workout Setup Timer Bottom Window Keypad Quick Start Option MAINTENANCE INSTRUCTIONS Helpful Hints Tool List Maintenance Records Initial Service Preventive Maintenance Cleaning Inspecting Lubrication Battery Charge Battery Disposal TROUBLESHOOTING General Troubleshooting Guidelines Electrical Troubleshooting 4600 4400 PT Alternator Test Diode Test Resistor Test 4600 4400 CL Battery Test Alternator Test Resistor Test 4600 4400 PT CL Console Diagnostics Display Test Speaker Test Keypad Test Speed Test Software Revision Level Test Contact Heart Rate Test Polar Heart Rate Test CONTENTS 28 28 28 30 30 3l 3l 32 32 32 32 33 33 33 33 34 35 35 37 37 37 37 38 39 39 39 39 40 40 41 41 41 41 42 42 43 43 CONTENTS Mechanical Troubleshooting PARTS REMOVAL AND REPLACEMENT Covers Mid Cover Top Cover Shield 4600 PT CL Bottom Cover Console Console Adjustment 4600 PT CL Poly V and HTD Belt Step Chain Reta iner Pedal Arm Retum Spring Step Chain Spring Pulley Drive Chain Drive Shaft Assembly Pedal Leveling Arm Pedal Arm Pedal Pad Eccentric Hub Assembly First Reduction Shaft Assembly Handlebar 4400 PT CL 4200 DII Upper Handles 4600 PT CL Side Handrails 4600 PT CL Alternator GROUNDING INSTRUCTIONS FCC COMPLIANCE APPENDICES Canad ian Doc Class B Compliance Important Phone Numbers Battery Recycling Centers Figu
9. The POly V pulley should spin freely If it does not replace the eccentric shaft assembly 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 Reinstall all parts ensuring the proper tension of the Poly V and HTD belts and the drive chain see Figure 30 Clean and lubricate the drive and step chains with 30W motor oil before reinstalling them Page 47 PARTS REMOVAL AND REPLAC COVERS 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 Access to the interior of the machine takes three steps remove the mid cover slide the top cover upward and remove the bottom cover see Figure 27 The 4600 PT CL has an additional shield over the handles Access to the interior of the machine takes four steps remove the mid cover remove the shield separate the top covers and remove the bottom cover Mid Cover 1 Use the fastener removal tool to remove each of the four fastener pins on the mid
10. 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 If within three years from the date of purchase any part of the StairMaster FreeClimber exercise system should fail to operate properly except any accessories or the battery on the 4600 and the 4400 Cl contact our Customer Service Department to report the problem When calling please be prepared to provide the customer service representative with the following information Your name customer number shipping address and telephone number model and serial number of the inoperable machine The date s of purchase for the inoperable machine s e Your billing address This information will ensure that you are the only one ordering parts under your warranty protection If warranty replacement parts are shipped to you you may be requ ired to return the inoperable part To facilitate this process the following policy has been established Please call our Customer Service Department to receive a retum goods authorization prior to shipment StairMaster Sports Medical Products Inc will incur all freight charges for warranty parts ordered for a machine that is less than 45 days old The parts will be shipped to you via an overnight courier You are responsible for freight charges on warranty parts for machines that are more than 4
11. Width at Front Leg 4600 PT CL Height Weight 4400 PT CL 4200 PT 4600 PT CL Power Supply Specifications 4600 4400 4200 PT U s Canada Japan 4600 4400 4200 PT International Battery Charger Specifications 4600 4400 CL U s Canada Japan 4600 4400 CL Intemational Internal Battery 6 volt 1 Ah Lead Acid battery 41 inches 104 cm 22 inches 56 cm 32 inches 82 cm 69 inches 176 cm 126 pounds 55 kg 155 pounds 70 kg 120 VAC 50 60 Hz 2 5 Amp 230 50 60 Hz 2 5 Amp 120 VAC 50 60 Hz 1 Amp 230 VAC 50 60 Hz 1 Amp PageS 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 Each face of the caps is a different thickness Twist the caps to stabilize the machine Rotate cap to adjust Level Adjusting End Cop 24329 Frame m Figure 3 Level Adjusting End Caps 3 Open the box you removed from the pedals The box contains either an external power supply 4600 4400 4200 PT only or a wall pack battery charger 4600 4400 CL only The battery charger is only u
12. belt tension according to the instructions in the Parts Removal and Replacement section 3 Remove the Poly V belt and move the pedal arms If the noise no longer exists check the condition of the alternator If the noise is still present go to step 4 Disconnect the DC power cable if you have a 4600 4400 4200 PT or unplug the connector from position J4 on the power supply circuit board if you have a 4600 4400 CL Spin the alternator pulley with your fingers It should spin freely and remain spinning for at least two revolutions If it does not the alternator should be replaced e Ifthe alternator does spin freely check the alternator for noise roughness or the presence of an excessive amount of black powder inside the alternator or near the outside of the case If any of these conditions exist the brushes might be bad and the alternator should be replaced 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 Page 45 4 MECHANICAL TROUBLESHOOTING 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 Remove the pedals Clean any corrosion off the pedal shaft with an oil dampened rag Apply a thin
13. bolt and nut Swing the alternator down 3 Remove the Poly V belt 4 Slide the HTD belt toward you and off the HTD pUlley Remove the belt from the machine 5 Reinstall the HTD belt Page 50 Adjust the HTD belt tension so that you have 1 4 inch 0 6 cm of side to side play wi th 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 the hub one hole clockwise e Install and tighten the four bolts and nyloc nuts e Verify the HTD belt tension Install the POly V belt Make sure it is centered on the pulleys Pivot the alternator up or down as necessary to allow 1 4 0 6 cm of belt deflection with fingertip pressure at the center of the vertical portion of either side ofthe belt see Figure 30 Tighten the alternator adjustment bolt Verify 1 4 0 6 cm of play in the belt and reinstall the bottom cover STEP CHAIN RETAINER 1 2 Remove the bottom cover Loosen and remove the two step chain retainer bolts These bolts are also the top two mounting bolts for the drive hub assembly Reverse the removal procedures to install the step chain retainer Make sure there is adequate clearance between the step chain and the step chain retainer PEDAL ARM RETURN SPRING 1 2 Remove the bottom cover Unhook the pedal arm return spring from the spring hanger Detac
14. by one or more of the following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help Z warnine CHANGES OR MODIFICATIONS TO EQUIPMENT NOT EXPRESSLY APPROVED BY STAIRMASTER SPORTS MEDICAL PRODUCTS INC COULD VOID THE USER SAUTHORITY TO OPERATE THIS EQUIPMENT CANADIAN DOC CLASS B COMPLIANCE This digital apparatus does not exceed the Class B limits for radio emissions from digital apparatus set out in the radio interference regulations of the Canad ian Department of Communications La present appareil numerique ne depasse pas les limites etablies pour les bruits radioelectriques applicables aux appareils numeriques de la Class B prescrites dans les reglement sur le brouillage radioelectrique dict par le Ministere des Communications du Canada Page 62 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 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
15. cover see Figure 28 2 Stand on the pedals and keep them on the floor 3 Slide the mid cover down and away from the machine Remove the cover from the frame tube Carefully let both pedals return to the upper stops lop Cover 1 4400 PIICI 4200PI Remove the mid cover and the console 4 Release the pins along the middle seam of the top cover Use a small phillips screwdriver or similar tool to push the fastener center pin in at least halfway Use your fingers to remove the fastener base from the cover and then separate the top covers Page 48 PART REMOVAL AND REPLACEMENT 5 4600 PI 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 PI CL Upper Hindle Assembly 1 Remove the two mounting screws from the bottom shield Top Shield a 18030 2 Separate the top shield from the PORT Shiga Bottom Cover bottom shield and remove the upper and lower shield from the handrail Screw 2X22216 Remove the mid cover N 4600 4200 4400 PT Disconnect the DC power cable from the connector located on the bottom side of the left bottom cover Remove the fastener located on each side of the lower edge of the bottom cover see Figure 27 4400 PI
16. period To return to your workout after a rest period simply raise either foot and start stepping again 4600 4400 CL and 4200 PT You can stop and rest as many times as necessary for up to thirty seconds at each rest period The console returns to the ATIRACT mode if you rest more than thirty seconds To return to your workout after a rest period simply raise either foot and start stepping again When you are finished with your workout the machine will slow down to the slowest speed Lift one foot slowly until the pedal arm contacts the upper stop Place that foot on the floor Repeat for the other foot Do not let the pedals slam into the upper stops since this may cause unnecessary wear and tear Cool down after you get off the machine by walking or stretching for at least five minutes Figure 5 Correct Exercise Posture Page 12 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 electron ic 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 The signal is converted into a heart rate which is displayed on the console The contact heart rate system is very accurate
17. pitch master link from the step chain connection points every three months Clean the master link and the bushing in the pedal arm Lubricate the master link and bushing with a thin coat of mUlti purpose grease before reassembling 6 Remove the pedal arms and leveling arms every three months Clean the pedal arm and leveling arm shafts and bushings with a clean cloth Protect the shafts from corrosion by wiping them with a cloth dampened with 30W motor oil 7 Remove the spring pulleys every three months Clean the spring pulley Page 34 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 reassembl ing 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 Battery Charge If you have a 4600 4400 CL remove the bottom cover and check the battery voltage level every three months 1 Using your multimeter touch the red lead to the positive terminal of the battery and the black lead to the negative terminal 2 If the voltage level is less than 6 1 VDC charge the battery Plug the wall pack battery charger into the connector located near the bottom of the left bottom co
18. the frame for any rust bubbling or paint chips during the weekly cleaning The salt in perspiration can damage the unpainted surfaces Page 33 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 Remove the bottom cover to get to the components 1 Place a protective mat on the floor while you lubricate your machine A rubber floor mat is available from StairMaster Sports Medical Products Inc 2 Lubricate the drive cha in and the step chains weekly Try to penetrate the entire length of the chains with 30W motor oil 3 Remove the drive chain and step chains every three months to thoroughly clean and lubricate them Use amild degreaser and a stiff brush to remove dirt and corrosion from the chains 4 Unhook the pedal arm return springs from the spring hanger every week To protect them from corrosion wipe the entire length of each pedal arm return spring with acloth dampened with 30W motor oil before reconnecting it Replace the spring if it is rusty or otherwise damaged 5 Remove the double
19. 00 hours g A Every 3 months or 900 hours Every 3 months or 900 hours 9 9 30W motor oil Multi purpose grease Multi purpose grease Multi purpose grease Clean oil dampened Multi purpose Note Use of lubricants other than those specified will result in diminished performance anda shorter life span for that part Page 36 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 The 4600 4400 PT electrical system has three major components the power sup ply the power cables and the console The 4600 4400 CL also has three major components the battery the power cables and the console The console power supply and battery are not serviceable by the owner If any of these parts are in operable they must be replaced Opening the console or the power supply will void the warranty 4600 4400 PT 1 Use a voltmeter set on VAC to verify that the AC wall outlet has 100 to 120 VAC or 220 to 240 VAC if applicable If you do not have a voltmeter plug in an alte
20. 12 19 VDC in pins 1 and 9 in the main cable connector Replace the main cable if the voltage reading is not the same as in step 7 10 If all voltage readings have been within the specified range and the console will not power up the console should be replaced Alternator Test 11 Check for loose wiring connections on the alternator diode and load resistor see Final Assembly Figure 12 Perform the Positive Output to Field test on the alternator the power off e Remove the white wire from the B terminal on the alternator e Remove the brown wire from the field terminal on the alternator e M Place a short wire with alligator clips on the B terminal and the field FLD terminal of the alternator e Step on the machine for approximately 10 15 seconds ffull resistance is achieved during this time your alternator has correct current flow If no resistance is achieved replace the alternator Page 38 SAY 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 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 Remove one wire from the load resi
21. 22075 Bracket Mai 2466608 2 in D 440007 2 x23054 dry 4 4271 Neck Insert 2x13580 22093 21616 MS 21590 D epi 1 22175 fan 22930 Alternator 22036 8 3 Pul dl A 2209 E X 22191 p 2 21182 21448 2 22080 4X 22006 Section BB x gt e Black T e Jw Step Chain Power Con nector 56 2X20198 Wh itd Gound 28 4 Pow9r Con necto X Main Cable 22075 22 Green 24271 1 44 Power Con nector Bracket rr to Chassis GlOund 24866 03 Pow9r Connector 24307 1 7491 jq essy 81 92264 5391913 Black Resistor toB Black A to Groun d Black 24802 08 Power nector to Ground Drive Chain 22347 i me Altemator 2190 03 Balt Main Cable Main Cable 21529 to Power Connector 4400 PT 21417 4x22047 4200 PT 21403 1 0025 0055 3 Ajquiassy jeur 61 2x24164 2 21 4 2 22326 9 Neck insert 21616 Speed sensor 21446 Wh ector Geen Power Connector 4x22075 0 Ground 22722090 Section 50 2x22075 12 00 491 Ajquiassy 04 017514 Neck assembly w grips to PCB Main Cable 24803 03 Main Cable 21415 Power Control Boa rd PCB N 4x2203B Black amp White Power Connector to PCB 19 00 Ajquassy
22. 425 823 1825 800 331 3578 FAX 425 823 9490 FAX 425 814 0601 INTERNATIONAL OFFICES AND DISTRIBUTORS For technical assistance and a list of distributors in your area please call or fax one of the following numbers INTERNATIONAL DIVISION 425 823 1825 FAX 425 820 7505 EUROPE HEADQUARTERS 41 91 827 3801 FAX 41 91 827 8902 GERMANY HEADQUARTERS 49 2204 610 27 FAX 49 2204 628 90 U K HEADQUARTERS 44 1908 221 323 FAX 44 1908 223 162 Page 63 BATTERY RECYCLING CENTER IN MAS N RACES 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 batter ies be recycled Do not throwaway 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 Auburn Hills MI 48326 7 1900 Oakcrest Ave Ste 5 T Page 64 ADDRESS 906 40th St Birmingham AL 35222 12860 W Cedar Dr Suite 106A 1721 C Oakbrook Dr NE Norcross GA 30093 2760 Aubum Rd 2882 Remico St SW Grandville Ml49418 17 Clinton Dr Hollis NH 03049 PHONE NUMBER 205 591 0606 818 333 3060 803 763 5833 708 352 3665 410 768 5586 617 932 6570 616 531 1120 612 631 2150 gl oj 2314 414 816 231 0685 603 886 5
23. 5 days old You will not be responsible for the return shipment of the inoperable parts Some inoperable warranty parts must be promptly returned to our Customer Service Department We will pay the shipping cost for the inoperable warranty parts Detailed instructions are included with each warranty replacement part StairMaster Sports Medical Products Inc neither makes assumes nor authorizes any representative or other person to make or assume for us any other warranty whatsoever whether expressed or implied in connection with the sale service or shipment of our products We reserve the right to make changes and improvements in our products without incurring any obligation to similarly alter products previously purchased In order to maintain your product warranty and to ensure the safe and efficient operation of your machine only authorized replacement parts can be used This warranty is void if parts other than those provided by StairMaster Sports Medical Products Inc are used Note Aerosol products cannot be transported via air Page viii 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 par
24. 62 Faf 2 x22326 White ar SOS 2x21774 Battery 4 14123 2 x24164 to PCB 4 24983 Blk amp Whito I Power Control Board to PCB 12 009p jquiessy jeu 015514 S33f1913 Reading Rack Upper Handle Assembly 2nS Black 18022 03 White 18022 01 EY Side Handrail Assembly Right 18017 03 Loft 18016 03 Lower Right Cover 4600 18052 06 4600 CL 18050 06 Lower Left Cover 4600 PT 18053 06 4600 CL 18051 06 12 14 009 5 102 61 9 61 Cover part numbers shown are for Black call Customer Service for additional part numbers abeg 21 abeg Snap Ring 2X21463 Washer Pedal Aim Left 100008 pia RE ight 10089 02 9 Pedal Am Assembly Right 10992 03 Left Pedal Arm shown assembled Snap Ring 2 2214 7 1 0029 72 14 0055 0095 gt 55 yeys 15114 Ajquiassy epag 9 21264 Transmission Sprocket 20006 First Reduction Shaft Assembly Exploded View Snap Ring 202 XL z e Eccentric Hub Assembly 24897 Exploded view gt o Left Drive Poly V Pulley 5 0 SD gt o 5 5 35 r go Sp 20197 20206 20198 20197 10382 20197 20198 20197 a 10383 3 lt 20197 a 20098 U From all Final Assembly drawings y 5 Drive Shaft Assembly 20197 Section 0 0 Exploded view 53429 9 8 22032
25. 900 26 Corporate Circe E Syracuse 13057 Rickenbacker ANG Bldg 1073 Columbus OH 43217 2635 Hamilton Ave Cleveland OH ea 3000 Mantras Ave 19605 320ConstanceDr gt Warminster 18974 920 VistaParkRd gt gt Pittsburgh PA 15205 41420 Ferrell Dr Ste 300 Dallas TX 75234 4738 Cotton Belt gt Antonio TX 78219 660 industry Dr Tukwila WA 98188 1666 2 1 Bluefield WV 24701 216 241 6231 216 241 6231 304 327 3594 901 396 5031 214 869 1855 210 66 5497 Page 65 FIGURES Figure 10 Parts Needing Periodic Maintenance Pedal Arm Retum Spring Pedal Arm Bushing Leveling Arm Bushing Pedal ArmS haft Page 66 Main Cable 247 A 3 X22047 COE 22070 22075 A H 22036 X x Handrail Assembly ES c Y Altemator ee Left 1801603 v B WARDS 2 X 22983 k Frame M i Pulley MOS Pis i 21587 xe STi Lhe ER P we 2x 22191 220097 Ij JJ 2x2030 21895 B 2 72 21192 Section BB 4X 22036 4X 22026 Neck Insert 4X 22075 21616 PowerCdnnector GG 24307 4X 22093 aw 1 009 91 Aiqveassy 912814 s34N9l4
26. ange your console with a console from the same type of machine you know is working and retest the machine If possible replace or exchange your contact heart rate handles with handles from the same type of machine that you know is working and retest the machine If you do not have spare parts contact the Customer Service Department at 800 331 3578 Polar Heart Rate lest 4600 4400 only The Polar 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 Polar heart rate Before you put the chest strap on wet the two contact patches Secure the chest strap as high under your pectoral muscles chest as is comfortable The chest strap should fit snugly comfortably and allow normal breath ing Page 43 2 4600 4400 PTICL CONSOLE DIAG While the console is in the ATTRACT mode noted by a simulated EKG signal in the console display or at the SELECT AWORKOUT prompt press HINCREASE 1 0 8 ENTER Aflashing should be displayed in the console text bar Your heart rate in beats per minute will show next to the heart icon If the heart icon does not show or if your heart rate is not displayed in the text bar then you have a problem with either the console chest strap or heart rate receiver Test your ches
27. ate cables 5 Reverse the removal procedures to install the new upper handle assembly SIDE HANDRAILS 4600 PI CL Upper Handle Assembly 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 Handrail Extrusion gt 3 Remove the four handrail 18019 adapter screws from the upper Handrail handle assembly 18008 4 Remove the upper handle assembly from the machine The contact heart rate cables are threaded through the handrai adapter Remove the handrail adapter from the contact heart rate cables Set the upper handle assembly aside 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 Handrail Adapter Access hole for the handrail adapter screw 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 fallout when one side is removed T Reverse the removal procedures to reinstall the handrail ALTERNATOR 1 Remove the bottom cover Mark by color the location of each wire attached to the alternator see Final Assembly Diagram Remove the wires from the alternator 2 Loosen and remove the altern
28. ator adjusting bolt on the slotted brace Remove the Poly V belt Inspect the belt for wear and replace the belt if it is cracked cut or is otherwise damaged 3 Loosen and remove the nyloc nut from the alternator post Remove the alternator from the frame 4 Reverse the removal procedures to install the new alternator Be sure to verify the wiring against the Final Assembly Diagram 5 Pivot the alternator up or down as necessary to allow 1 4 0 6 cm of belt deflection with finger tip pressure at the center of the vertical portion of either side of the belt see Figure 30 Page 60 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 IMPROPER CONNECTION OF THE EQUIPMENT GROUNDING CONNECTOR CAN RESULT IN THE RISK OF ELECTRIC SHOCK CHECK WITH A QUALIFIED ELECTRI CIAN OR SERVICE PERSON IF YOU ARE IN DOUBT AS TO WHETHER THE MA CHINE IS PROPERLY GROUNDED DO NOT MODIFY THE PLUG PROVIDED WITH THIS MACHINE IF IT WILL NOT FIT THE AVAILABLE OUTLET HAVE A PROPER OUTLET INSTALLED BY AQUALIFIED ELECTRICIAN The grounding plug on the power supply and the battery charger is sh
29. ble in the reverse order Ensure the belts are properly tensioned refer to the Poly V and HTD belt section FIRST REDUCTION SHAFT ASSEMBLY 1 2 Remove the bottom cover Remove the drive chain Remove the eccentric shaft assembly Remove the set screw from the transmission sprocket see Figure 20 Remove the sprocket and key from the shaft Hold onto the HTD sprocket and pull the shaft out of the hub Reassemble in the reverse order Ensure the belts are properly tensioned refer to the Poly V and HTD belt section HANDLEBAR 4400 PI CL 4200 PT 1 2 4 Remove the console and separate the left and right top cover Cut the Ty wraps that secure the main cable to the handlebar tube Remove the four screws and flat washers that hold the handlebar tube in the frame tube see Final Assembly Figure Lift the handlebar out of the frame Reverse the steps to reinstall the handlebars Page 58 UPPER HANDLES 4600 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 Remove the handrail adapter from the contact heart r
30. coat of mUlti purpose grease to the shaft If the noise persists go to step 6 Check the step chain connection point Clean and grease the master link and bushing Replace damaged parts Check the drive hub assembly e Check the condition of the drive sprocket teeth The teeth should not be unevenly worn Replace the worn sprocket s e drive sprockets work independently of one another Each sprocket should turn freely in one direction and lock when turned in the other direction Replace an inoperable drive sprocket e Remove the drive shaft Inspect the bearings in the drive hub Replace the drive hub assembly if the shaft does not spin freely or if there is excessive radial play at the shaft Be careful not to get dirt into the hub e Inspect the ends of the drive shaft at the sprocket attachment points for signs of wear or scoring Replace the shaft if it is excessively worn Check the pedal arm and leveling arm shafts by removing both the right and left pedal and leveling arms Inspect the shafts and the bushings for signs of wear and corrosion Replace the bushing s if worn 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 Page 46 10 Remove the HTD belt Inspect the belt the Poly V pulley and the HTD pulley for excessive wear Replace if necessary
31. d in RPMs is displayed on the text bar as Target and a single column of lights will light up on the left side of the display 3 Begin exercising As you move the pedal arms the text bar will alternately show the actual RPM and the target RPM 4 Press CLEAR to retum to the DIAGNOSTIC mode Software Revision Level Test This test allows you to check the version number of the software installed in the console 1 From the DIAGNOSTIC mode press 4 to start the test 2 The software version number will be scrolled across the text bar The console automatically returns to the DIAGNOSTIC mode Page 42 65539 2 4600 4400 PTICL CONSOLE DIAGNOSTIC TESTS Contact Heart Rate lest 4600 4400 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 ATIRACT mode noted by a simulated EKG signal in the console display or at the SELECT WORKOUT prompt press INCREASE 1 0 8 ENTER After approximately ten seconds a flashing should be displayed in the console text bar Your heart rate in beats per minute will show next to the heart icon If the heart icon does not show or if your heart rate is not displayed in the text bar you have a problem with either the console or the contact heart rate handles If possible replace or exch
32. ds Floors Shows the total number of floors you have climbed There are 16 eight inch steps per floor Distance Provides the equivalent horizontal distance you would have traveled if you used the same amount of energy There are 48 floors per horizontal mile Watts Displays the power output in watts 746 watts 1 horsepower Since power is arate watts will not accumulate over time During a workout this key displays the power output at that moment Average power is shown for the workout summary Page 16 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 MEls 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 For example exercising at 10 METs requires ten times the resting rate of oxygen consumption or about 35 milliliters per kilogram per minute During a workout this key shows the current MET level During the workout summary the average MET level is displayed Calories Provides a running total of the number of Calories bumed during a workout Step Rate Indicates the climbing speed in steps per minute It is based on an average eight inch step Enter Con
33. e Page 21 FREECLIMBER 4600 4400 CONSOL 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 arejust starting to exercise or for those who need an easy day of recovery exercise The AEROBIC TRAINING program is a 60 interval workout with slightly more varied speed changes It is ideal for those long slow workouts to increase your aerobic capacity The CROSS COUNTRY and SPEED TRAINING programs are 90 interval workouts with lots of speed changes to get your legs moving Think of the terrain you would find on a hike cross country THE JACKPOT OPTION When you finish your workout a GOAL ATTAINED message is normally displayed in the text bar This message may be replaced by a Native American casino style slot machine When the wheels of the slots stop turning the console display will spell out either YOU WIN or THE END The odds of winning may be programmed anywhere from l in l to l in 999 The computer will then randomly select a winner and display YOU WIN otherwise it will display THE END Workout statistics are shown as usual after the jackpot message Commercial
34. e 22 Covers 4400 PTICL 4200 PT 78 Figure 23 Cover Removal 79 Figure 24 Cover fasteners 80 Figure 25 Drive Chain tensioning 81 Figure 26 Belt Tension 82 Page xiii SAFETY GUIDELINES WHEN USING ELECTRICAL EQUIPMENT ALWAYS FOUOW THESE BASIC PRECAUTIONS IMPORTANT SAFETY INSTRUCTIONS N 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 WARNING Used to call attention to POTENTIAL hazards that could result in personal injury or loss of life READ ALL INSTRUCTIONS BEFORE USING THE MACHINE N DANGER reduce the risk of electrical shock always unplug the external power supply from the AC wall outlet before cleaning maintaining or repairing b uw To reduce the risk of bums electric shock or injury to persons The extemal power supply should always be unplugged from the AC wall outlet before removing or installing parts Never make adjustments or repairs while an exercise program is in progress Close supervision is necessary whenever the machine is used by or near children invalids or disabled persons Keep your hands away from all moving parts and keep your feet on the pedals while exercising Do not operate the mach
35. e MANUAL program Use the or ARROW to change the workout option P2 corresponds to Steady Pace P3 to Fat Bumer and P4 to Aerobic Training The different workout option profiles are shown on the right side of the console When the correct workout option is displayed on the top LCD window press ENTER SELECT The arrow pointing to the word Weight will flash and the number 150 will be displayed Use or ARROW to adjust it to your body weight Press ENTER SELECT when it is correct If you selected aworkout option other than PI MANUAL the arrow pointing to the words Speed Level will flash and the number 10 will be displayed Adjust the level between 1 the slowest and 20 the fastest with or ARROW Press ENTER SELECT when it is correct If you selected MANUAL your workout will start at speed level 3 Levell is the slowest and level 20 is the fastest Use the or ARROW to adjust the climbing speed once your workout begins The arrow pointing to the word Time will flash and the number 15 will be displayed Press or ARROW to adjust the length of your workout between 5 and 45 minutes Press ENTER SELECT Begin exercising Page 29 ME E FREECLIMBER 4200 PT CONSOL Timer During your workout the top window keeps track of your workout time in min utes and seconds The display arrow points to the word Time on the console You may rest for up to 30 seconds at any tim
36. e ashort wire with alligator clips on the B terminal and the field FLD terminal of the alternator e Step on the machine for approximately 10 to 15 seconds ffull resistance is achieved during this time your alternator has correct current flow If no resistance is achieved replace the alternator Resistor Test 6 Unplug the load resistor from the power control board and set your voltmeter to Ohms Place one lead from the voltmeter on each of the threaded posts on the load resistor Replace the load resistor if the voltmeter does not read 2 5 Ohms 10 7 Ifthe problem still exists contact the Customer Service Department at 800 331 3578 Page 40 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 Display Test Use this test if the console display or text bar exhibits blank spots during use This test checks for inoperable Light Emitting Diodes LEOs in the console dis play and the text bar If any LED will not light replace the console 1 From the DIAGNOSTIC mode press 0 to start the test 2
37. e bottom cover 2 Unhook the pedal arm retum spring from the spring hanger 3 Remove the snap ring from the pulley shaft see Figure 10 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 athin coat of multi purpose grease to the pulley shaft 6 Slide the pulley and washer onto the shaft Install the snap ring Route the spring under the spring pulley 8 Hook the end of the spring over the spring hanger Do not twist the spring DO NOT TWIST THE SPRING DURING INSTALLATION IT WILL WEAR EXCESSIVELY AND REDUCE THE LIFE OF THE SPRING 9 Reinstall the covers DRIVE CHAIN 1 Remove the bottom cover Page 53 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 1to 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 IF THE DRIVE CHAIN IS TOO TIGHT THE DRIVE TRAIN WILL WEAR EXCESSIVELY SHORTENING THE LIFE OF THE DRIVE HUB IF THE CHAIN IS TOO LOOSE THE MACHINE WILL BE NOISY AND WILL OPERATE AT LESS THAN PEAK EFFICIENCY 6 Lubricate the chain with 30W motor oil and wipe off the excess T Reinstall t
38. e 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 AITRACT mode BOTTOM WINDOW The bottom LCD window keeps track of four different statistics during your work out 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 bumed during a workout Steps Min Indicates the climbing speed based on an eight inch step Floors Shows the total number of floors you have climbed There are 16 eight inch steps per floor Distance Provides the equivalent horizontal distance you would have traveled if you used the same amount of energy There are 48 floors per horizontal mile When the display arrow points to the word Scan all workout statistics are scrolled Press ENTER SELECT during your workout to lock the bottom display window on anyone statistic For instance press ENTER SELECn three times to lock the display on the total number of floors climbed Press ENTER SELECT two more times to resume scrolling the statistics During rest periods only Calories Floors a
39. e intensity level and the workout time when you use the custom program Custom programs have a quick start option but the time is limited to five minutes Programming Your Workout 1 The console must be in the ATTRACT mode Press INCREASE 1 6 5 0 ENTER Press the exercise program keypad button that you want to assign to your custom program If you select an exercise program keypad button that is already programmed the profile will appear it can be modified or completely rewritten If the exercise program keypad button was not previously programmed you will see a single row of dots along the bottom of the display The flashing dot or column indicates wh ich interval can be modified Press the INCREASE or DECREASE to make the column Page 23 FREECLIMBER 4600 4400 taller or shorter Press ENTER move one column to the right and CLEAR to move one column to the left When all of the intervals are correctly programmed press 0 4600 PTfCI or YES 4400 PTfCI to save the profile Press STOP 4600 PTfCI or STARTfSTOP 4400 PTfCI 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 Enter your body weight the intensity level and the workout time in response to the prompts CUSTOM SCROLLING MESSAGE The message that scrolls acro
40. e on or off 0 Tums the Heart Rate feature on 1 Tums the Heart Rate feature off 9760 Allows you to change the units displayed by the console 0 Changes the console to English units 1 Changes the console to metric units 9766 Allows you to change the software version 0 Changes to 4400 PT software 1 Changes to 7000 PT software 97405 Changes the maximum workout time 52475 Reset time limit to 60 minutes Page 27 FREECLIMBER 4200 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 i Bids em oF try o Bus Pogue ma V A dien ma V r ano rn v Figure 8 4200 PT Console Diagram TOP WINDOW The top LCD window displays information while you set up your workout It also displays elapsed time during your workout or during your rest period Workout Setup 1 While the console is in the ATTRACT mode either press START STOP or step on the pedals Look at the top LCD window Page 28 FREECLIMBER 4200 PT CONSOLE The arrow pointing to the word Program should be flashing and PI should be displayed corresponds to th
41. er LCD window If the console does not unplug the power supply and then plug it back in If the console still does not power up correctly contact our Customer Service Department Refer to the Appendix for the appropriate phone number 9 If you have a 4600 4400 CL step on the pedals to check for proper operation Once you step on the pedals the console should produce an audible sound and display a simulated EKG in the display area If it does not connect the battery charger to the connector on the lower right side If the console still does not power up contact our Customer Service Department Refer to the Appendix for the appropriate phone number 10 The ATTRACT mode tells you the machine is ready to use The 4600 4400 console displays a simulated EKG signal and the 4200 PT displays a moving line in the upper LCD window when the console is in the ATTRACT mode PageS THESE GUIDELINES ARE DIRECTED TO YOU AS THE OWNER 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 When working out for the first time use the MANUAL exercise program at the lower speeds until you feel comfortable and capable of faster speeds 3 The speed and duration of your exe
42. es with the program Quick starting MANUAL gives you a 15 minute workout The preprogrammed workouts last five minutes for every thirty intervals For example a 60 interval program will last 10 minutes All workout stats displayed at the end of a workout are based on a 175 Ib body weight The CONSTANT HEART RATE program key on the 4600 PT CL and the FIT TEST program key on the 4400 PT CL do not have a quick start option The Fit Test The Fit Test is a program that estimates your maximal aerobic capacity based on your heart rate response to submaximal exercise Start the 4600 PT CL Fit Test by pressing INCREASE 3 4 8 ENTER while the console is in the ATTRACT mode Start the 4400 PT CL Fit Test by pressing FIT TEST ENTER while the console is in the ATTRACT mode You will be prompted to enter your age and gender after a short message is scrolled across the display Once you have entered the required information you will step at the rate of 43 steps per minute for three minutes At the end of three minutes you will need to enter your heart rate if you are wearing a heart rate transmitter and using a 4600 or 4400 CL your heart rate is entered automatically Page 19 Note Keep stepping until the end ofthe Fit Test The Fit Test will end ifyou 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 cou
43. firms workout selections and stores the information used by the console to calculate workout statistics Zero On 4600 4400 PTICL models press this key to see your heart rate during your workout Press it during the workout summary to see your average heart rate Clear Erases information from the console memory if pressed before ENTER INCREASE DECREASE Increases or decreases the intensity level 4400 PI CL Respond to console prompts Start 4400 PI CL If pressed while the console is in the ATTRACT mode the console will display the Select A Program prompt Page 17 Stop If pressed at any time the console will retum 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 If pressed while the console is in the ATTRACT mode the final totals from the last workout if the workout was 10 seconds will Scroll across the text bar This summary is stored in the console memory until the next work out is started ENTERTAINMENT KEYPAD 4600 PT CL The 4600 PT CL comes equipped to facilitate the use of commercial entertainment systems Volume 7 Increases or decreases the volume level M
44. h the spring from the step chain by removing the master link The spring chain connector is in good condition if it has an hour glass shape Replace a worn spring chain connector Page 51 PARTS REMOVAL AND 4 Check to ensure that the spring pulley tums 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 ofthe 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 T Hook the end of the pedal arm retum spring onto the spring hanger N WARNING DO NOT TWIST THE SPRING DURING INSTALLATION IT WILL WEAR EXCESSIVELY AND REDUCE THE LIFE OF THE SPRING 8 Reinstall the covers STEP CHAIN 1 Remove the bottom cover 2 Remove the step chain retainers 3 Support the pedal arm Unhook the pedal arm retum 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 double pitch master link PN 21298SV and bearing sleeve assembly from the step chain connection point on the pedal arm 5 Remove the master link from the spring chain connection 6 Reverse the procedures to reinstall the step chain Lubricate the step chain before reinstalling the covers Page 52 ys PARTS REMOVAL AND REPLACEMENT SPRING PULLEY 1 Remove th
45. he covers DRIVE SHAFT ASSEMBLY 1 Remove 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 Repeat on the other side 4 Remove the snap ring from the left end of the drive shaft ZX WARNING TO REDUCE THE RISK OF EYE INJURY WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS Page 54 10 EE ARTS REMOVAL AND REPLACEMENT Remove the drive chain Remove the sprocket and the other small parts from the left side of the hub assembly see Figure 21 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 Loosen and remove the two remaining bolts and nuts that hold the hub assembly to the frame Remove the hub assembly Inspect the drive shaft the bushings the thrust washers and clutch Sprockets for excessive wear or pitting Replace worn out components To reinstall the hub assembly carefully reverse the disassembly procedures Be sure that the right and left hand clutch sprockets are positioned correctly the wide shoulder of the sprocket should be facing away from the hub on both sides Chain Tension The drive shaft is mounted in an eccentric hub Rotate the hub so the marked hole is in the 12 o cl
46. how a few hours of use due to testing at the manufacturing facility Page 32 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 Refer to the Installation Instructions section for details PREVENTIVE MAINTENANCE Most of these preventive maintenance procedures can be performed after removing the mid cover The preventive maintenance schedule is summarized in Table 5 The schedule is based on normal usage in a commercial health club environment adjust the schedule to meet actual machine usage Refer to the Parts Removal and Replacement section for all disassembly and assembly instructions Cleaning 1 DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANER ON THE CONSOLE Clean the console daily with a water dampened cloth and wipe dry after cleaning 2 Clean the exterior of the machine daily using soap and water or a diluted household cleaner such as Fantastic 3 Thoroughly clean the entire machine including the interior at least once a week see Table 5 Inspecting 1 Inspect
47. ine with the side covers removed Page 1 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 Refer to the Appendix for the appropriate phone number 6 Connect the extemal power supply to a properly grounded AC wall outlet refer to the Grounding Instructions section Keep all cords away from heated surfaces 7 To disconnect the external power supply remove the plug from the AC wall outlet 8 Never drop or insert any object into any opening on the machine 9 Do not operate where aerosol spray products are being used 10 Always wear insulated gloves when handling batteries 11 Do not crush incinerate or dismantle the battery The electrolyte contains sulfuric acid which can cause serious damage to eyes and skin Should this occur flush profusely with water and seek medical attention 12 Do not use the machine outdoors The safety level given by the design of this equipment can only be maintained when the equipment is regularly exam ined for damage and wear Inoperable components shall be replaced immediatel
48. m 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 The FAT BURNER program is a60 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 AEROBIC TRAINING program is a 60 interval workout with Slightly more varied speed changes It is ideal for those long slow workouts to increase your aerobic capacity The CONSTANT HEART RATE program maintains a chosen target heart rate by automatically varying the climbing speed during each workout The default target heart rate selected by the console is equal to 7096 of your maximum heart rate which is calculated by the following equation 220 Age 70 You may choose a different target heart rate that is between 100 and 170 beats per minute 4400 PT CL There are seven 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 sam
49. nd Distance are shown even if the display was locked on one statistic At the end of your workout these same three statistics are shown one last time Page 30 Keypad FREECLIMBER 4200 PT CONSOLE 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 anyone 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 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 QUICK START OPTION You can quickly start the MANUAL program IP1 by pressing ENTER SELECT twice double clicking at the start of workout setup The workout statisics are based on a 150 pound person the climbing speed starts at level 3 and the workout time is set to 15 minutes Use the or ARROW to adjust the climbing speed once your workout starts Page 31 MAINTENANCE INSTRUCTION HELPFUL HINTS Read all maintenance inst
50. nd the exercise program keypad see Figures 6 87 TQXt Bar gt StirMaster CLIMBING SYSTEMS LC Taa WWW 310 7 23187 com n START TY 2 8 2 Functioa ig user ry 0 Keypad joe mas DEN li e i Ie E REN EIE amen e Program Display Figure 6 4600 PI CL Console Diagram Function Kaypa Figure 7 4400 PI CL Console Diagram Page 15 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 The flashing column shows your current interval The flashing column moves from left to right across the display as you complete each interval FUNCTION KEYPAD The white function keypad is located on the right side of the console Some of the keys have two functions data entry and workout statistics Before you start your workout use the numbers on the keys to enter your personal data During and after your workout use the workout statistics on the keys to display the feedback Time Displays the elapsed time of your workout in minutes and secon
51. nting 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 You will continue to exercise for three minute bouts of increas ing inten sity until you reach a point where you have entered two heart rate responses be tween 19 and 25 counts 115 150 beats per minute The test typ ically lasts from nine to 15 minutes At the end of the Fit Test your results scroll across the text bar Prior to athree minute cool down your estimated aerobic capacity expressed in METs is shown Next your results will be compared to normative values for others of your age and gender These normative values are based on values developed by the world renowned exercise physiologist Dr Per Olaf Astrand and are shown in Table 2 Your results are stored inthe console until the next person starts an ex ercise program Press WORKOUT STATS to review your results Table 2 Fitness Rating Norms METs RatinQ low Fair Average Superior 1 1 123 126160 16 3 19 7 100 1 1 114 146 14 8 18 3 8 8 1Q0 Q 103 134 14 0 16 8 13 7 16 6 13 1 160 12 0 14 0 10 6 12 6 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 progra
52. ock position lining up four holes in the hub with the four holes in the frame Use this hub position when reinstalling the drive chain since the distance between the drive and transmission shafts is at a minimum The hub is in the proper position when the drive chain has a total of 1 to 1 1 2 2 5 to 4 0 cm of play at the slackest point As the drive chain stretches with use increase the chain tension and the distance between the two shafts by rotating the hub counterclockwise see Figure 29 The distance between the two shafts is greatest when the marked hole in the hub is at the 8 o clock position Reinstall the covers Page 55 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 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 athin coat of multi purpose grease 4 Reverse the procedures to reinstall the pedal LEVELING ARM 1 Remove the 2 Remove the bottom cover 3i Remove the snap ring that secures the leveling arm to the leveling arm shaft see Figure 18 AN WARNING TO REDUCE THE RISK OF EYE INJURY WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS Slide or gently tap the leveling arm off the shaft 5 Clean the shaft and the pin with a cloth dampened with 30W motor oil before reassembly 6 Re
53. or instructions 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 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 Hold onto the handlebars and step up onto the pedals Stand up straight The pedals will sink slowly toward the floor 3 Select the MANUAL exercise program so you can control the pace of your first workout and get used to the exercise motion 4600 4400 PT CL Console Set Up 1 Press MANUAL and then press ENTER The console will return to the ATTRACT mode if you do not press ENTER within ten seconds Page 10 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 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 4200 PT Console Set Up 1 Look at the upper LCD window The arrow pointing to the word Program should be flashing and PI sho
54. our 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 Once the receiver locks on to your signal it will ignore all other signals without your identification number Now two people can exercise side by side without interfering with each other s heart rate signal Before you put the transmitter belt on wet the two contact patches the grooved rectangles on the reverse side of the belt Secure the transmitter belt as high under the pectoral muscles chest as is comfortable The transmitter belt should fit snugly and comfortably and allow normal breathing When the console detects a heart rate signal heart rate is shown in the display automatically The word PULSE your heart rate in beats per minute and a pulsing heart icon are displayed in the text bar If you display a statistic other than heart rate during your workout you can return to heart rate by pressing the white 0 key Heart rate is part of the workout stats scrolling display Average heart rate is shown at the end of your workout If you wear a transmitter strap during the Fit Test the average heart rate at the end of each stage is automatically used when estimating maximum aerobic capacity Page 14 FREECLIMBER 4600 4400 PVCL CONSOLE The StairMaster FreeClimber 4600 4400 PTICL console is divided into four sections the text bar display the function keypad a
55. own in sketch A below A temporary adapter shown in sketches Band C may be used to connect the plug to atwo pole receptacle if a properly grounded out let is not available The adapter should be used only until a properly grounded outlet sketch A can be installed by a qualified electrician The tab extending from the adapter must be connected to a permanent ground such as the metal Screw on the outlet cover This may vary for International power supplies 3 prong grounded outlet box Grounded outlet prong outlet box Adapter Tab for grounding screw A Grounding pin Metal screw B Figure 9 Grounding System Page 61 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 instal lation 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 rad io communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be deter mined by turning the equipment off and on the user is encouraged to try to cor rect the interference
56. owners often use the jackpot option to further stimulate consumer interest in their establishment and to add variety to their overall workout program Many such owners offer a prize or some tangible incentive for individuals who win while using the jackpot option If there is only one prize you should remember to disable the option after there is a winner The jackpot option remains in effect until disabled by entering zero odds StairMaster assumes no liability stemming from the use of thejackpot option Laws or ordinances in your area may govern the use of this option Page 22 222 SES FREECLIMBER 4600 4400 PI CL CONSOLE Turning the Jackpot Option On and Off 7 The computer must be in the ATTRACT mode Press INCREASE 7707 ENTER The prompt ENTER ODDS will appear the console display Enter the numeric odds you have selected between 1 and 999 The jackpot results are saved in the console memory unti next workout is started Press WORKOUT STATS to review the results Program the odds to zero to tum the jackpot option off and to return to having the GOAL ATTAINED message appear after you finish your workout CUSTOM EXERCISE PROGRAMS The 4600 PT CL console has enough memory space for six custom exercise programs The 4400 PT CL console has enough memory space for nine custom exercise programs Only the exercise profile is saved You must enter your body we ight th
57. rcise program should always be subject to how you feel Never permit peer pressure to exceed your personal judgment whi le exercising 4 Overweight or severely deconditioned individuals should be particularly cautious when using the machine for the first time Even though such individuals may not have histories of serious physical problems they may perceive the exercise to be far less intense than it really is resulting in the possibility of overexertion or injury 5 Although all equipment manufactured by StairMaster Sports Medical Products Inc has been thoroughly inspected by the manufacturing facility prior to shipment proper installation and regular maintenance are required to ensure safety Maintenance is the sole responsibility of the owner Page 9 BASIC OPERATING INSTRUCTI 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 PTICL console displays an EKG signal or scrolls a message in the text bar when it is in the ATIRACT 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 You can customize the ATTRACT mode on the 4600 4400 PTICL by programming your own scrolling message Refer to the Customizing the Text Bar Scrolling Message section f
58. res 10 30 Page xii 45 48 48 48 48 49 49 50 50 50 51 91 52 53 53 56 56 57 57 58 58 58 59 59 60 61 62 62 63 66 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 36 LIST OF ILLUSTRATIONS Figure 1 Major Parts 4600 PT CL 3 Figure 2 Major Parts 4400 PT CL 4 Figure 3 Level Adjusting End Caps 6 Figure 4 DC Power Connector 7 Figure 5 Correct Exercise Posture 12 Figure 6 4600 PT CL Console Diagram 15 Figure 7 4400 PTICL Console Diagram 15 Figure 8 4200 PT Console Diagram 28 Figure 9 Grounding System 61 Figure 10 Parts Needing Periodic Ma intenance 66 Figure 11 Final Assembly Left 4600 PT 67 Figure 12 Final Assembly Right 4600 PT 68 Figure 13 Final Assembly Left 4600 CL 69 Figure 14 Final Assembly Right 4600 CL 70 Figure 15 Covers 4600 PT CL 11 Figure 16 Pedal Arm Assembly amp First Reduction Shaft Assembly 4600 4400 PTICL 4200 PT 72 Figure 17 Drive Shaft Assembly amp Eccentric Hub Assembly 46004400 PT CL 4200 PT T3 Figure 18 Final Assembly Left 4400 4200 PT 74 Figure 19 Final Assembly Right 4400 4200 PT 75 Figure 20 Final Assembly Left 4400 CL 76 Figure 21 Final Assembly Right 4400 CL TT Figur
59. rnate AC powered device a lamp for example If the device does not work when plugged into the AC wall outlet consult an electrician for further assistance and then retest the AC wall outlet 2 Plug the power supply into the wall outlet The green Light Emitting Diode LED on the power supply should be on If the LED does not light up replace the power supply 3 Disconnect the DC cable from the left side panel Set the voltmeter to VDC and test for 12 19 VDC in pins 1 and 2 Replace the power supply ifthe voltage reading is outside the specified range 4 Remove the bottom cover and connect the DC cable to the power connector on the left side of the frame Locate the black and white wires on the backside of the power connector Page 37 A i W 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 DC voltage measured should be 12 19 VDC Replace the power connector if the voltage is not the same value as in step 3 Connect the two white wires 8 Remove the console knobs from the back of the console lift the console up and disconnect the main cable from the console 9 Test for
60. ructions thoroughly before beginning work In some cases an assistant is required to perform the necessary tasks 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 When ordering parts reference the part number in parentheses next to the part s description on the figures TOOL LIST The following tools are needed to perform service and maintenance standard screwdriver phillips screwdriver e combination wrenches sizes 7 16 3 4 adjustable wrench combination pliers locking pliers volt ohm meter multimeter wire stripper crimper tool allen wrench set sizes 5 64 1 4 extemal snap ring pliers shop goggles or other eye protection torque wrench Socket set or nut driver set sizes 1 4 3 4 in 1 16 increments MAINTENANCE RECORDS The 4600 4400 PT CL console will keep track of the following data on machine usage The number of hours the power supply was turned on The number of hours the machine was in use The total number of floors climbed The number of exercise programs started The hours of MANUAL use To display the data press INCREASE 7 7 0 3 ENTER while the console is in the ATTRACT mode The console will display the data in the sequence listed above The machine may s
61. sed to recharge a low battery Page 6 INSTALLATION INSTRUCTIONS If you have a 4600 4400 CL skip to step 9 If you have a 4600 44001 4200 PT connect the DC cable of the power supply to the connector near the bottom of the left side cover see Figure 4 Connect power supply here Figure 4 DC Power Connector 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 You should not place your power supply on a carpet because it may over heat Page 7 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 TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO PREVENT SEVERE DAMAGE TO THE MACHINE USE ONLY THE POWER SUPPLY AP PROVED FOR USE WITH THIS EQUIPMENT IN ADDITION YOUR MACHINE MUST BE PROPERLY GROUNDED T Connect the AC power cord to the AC wall outlet Refer to the Grounding Instructions section ifthe AC wall outlet does not accept athree prong plug 8 Watch the console The 4600 4400 PT should scroll a copyright message and then display a simulated EKG signal The 4200 PT console should run through a self test and then display a moving line in the upp
62. ss the text bar during the ATTRACT mode can be replaced with a message of your choice The console accepts messages up to 128 characters in length including spaces To program your message 1 2 5 Encode your message using the character codes listed in Table 3 While the console is in the ATTRACT mode press INCREASE 7 6 0 7 ENTER Enter the two digit code for each letter of your message The letter will appear in the text bar as you press the second digit of each code Do not press ENTER between the code numbers For example to program the message EXERCISE IS FUN press ARROW 7 6 0 7 ENTER Then press 1 5 3 4 1 S 2 8 1 3 1 9 2 9 1 5 1 0 1 9 12 9 1 0 1 6 3 1 2 ENTER At that point your message will begin scrolling The console is again in the ATTRACT mode If you make a mistake while entering the codes press CLEAR to erase the last character entered Page 24 5 FR ECLIMBER 4600 4400 CONSOLE Table 3 Character Codes for the Scrolling Message 0 00 M 23 46 1 01 N 4 4 2 0 0 25 48 3 03 E 49 4 04 Q 7 A 50 5 05 R 28 5 6 06 S 29 52 7 07 30 53 8 08 U 31 M 54 9 9 V 32 55 SPACE 10 w 33 56 A X 57 12 Y 35 58 13 2 59 D M A 37 60 E 15 0 38 6l F 16 0 39 62 G 17 B 4 63 H 18 A 4l 64 19 2 65 J 20
63. ster FreeRunner Introducing the StairMaster FreeRunner 5400 ESS arevolution ary new design that allows you to vary your stride length from 10 to 40 Not only does this unique VSL feature accommodate all users it also provides enhanced lower body conditioning with greater involvement of the glutes quadriceps and hamstrings For total body condition ing club members will love the fact they can use the handles on the StairMaster FreeRunner 5400 for an effective upper body workout These handles can also be easily disengaged to rest on the side of the machine TREADMILLS The Highest Quality In response to many requests we received from our customers for ahigh 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 Club Track 612 and the ClubTrack 612 Plus Only Quinton could match the StairMaster reputa tion for maximum performance durability and product safety Page vi STRATUS EXERCISE BIKES New Models amp Prices At last acordless line of variable resistance exercise bikes that not only provide the exciting workout programs that StairMaster is famous for but are designed with such uncompromising attention to every biomechanical detail they offer you extraordinary safety and comfort Introducing Stratus exercise bikes a new cordless
64. stor see Final Assembly Figure and place one lead from the voltmeter on each of the threaded posts on the load resistor Replace the load resistor if the voltmeter does not read 0 5 Ohms 10 4600 4400 CL Battery Test 1 Remove the mid cover and top covers and unplug the battery from the power control board Locate pins 1 amp 2 in the end of the cable Use voltmeter to verify that the voltage is a minimum of 6 1 VDC Reconnect the battery back to the power control board and install the battery charger for at least 24 hours if the voltage measured is below 6 1 VDC Remove the console knobs from the back of the console lift the console up and disconnect the main cable from the console Step up on the machine With the voltmeter set to DC voltage test for greater than 6 1 VDC in pins 1 and 8 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 If all voltage readings have been within the specified range and the console will not power up the console should be replaced Page 39 ELECTRICAL TROUBLESHOOTING Alternator Test 5 Perform the Positive Output to Field test on the alternator Unplug the battery from the power control board e Remove the white wire from the B terminal on the alternator e Remove the brown wire from the field terminal on the alternator Plac
65. t The 4600 CL and the 4400 CL use power gener ated during a workout to run the electronics The 4600 PT and 4600 CL have contact heart rate and Polar amp heart rate monitoring The 4400 PT and the 4400 CL feature Polar heart rate monitoring The 4200 PT uses an external power supply to run a Liquid Crystal Display LCD console This LCD console has less feedback and fewer workout programs than the LED console the 4600 PTICL and the 4400 PT CL Pageix CONTENTS SAFFETV GUIDELINES INTRODUCTION INSTALLATION INSTRUCTIONS BASIC OPERATING INSTRUCTIONS General Guidelines for Safe Operation Your First Workout The ATIRACT Mode Basic Instructions for First Time Users 4600 4400 PT ICL Console Set Up 4200 PT Console Set Up Begin Exercising CONTACT HEART RATE 4600 PTICL ONLY POLAR HEART RATE 4600 4400 PTICL ONLY FREECLIMBER 4600 4400 PTICL CONSOLE Text Bar Display Function Keypad Entertainment Keypad 4600 PT ICL Exercise Program Keypad The Quick Start Option The Fit Test Preset Exercise Programs 4600 PTICL 4400 PTICL The Jackpot Option Tuming the Jackpot Option On and Off Custom Exercise Programs Programming Your Workout Using a Custom Program Custom Scrolling Message Editing The Scrolling Message Changing the Console Units and Language Console Codes Page x 10 10 10 10 11 13 14 15 16 16 16 18 18 19 19 4 4 21 22 23 23 23 24 24 25 26 26 FREECLIMBER 4200
66. t of this manual includes sections on safety installation operating instructions and preventive maintenance The second part contains detailed information on problem troubleshooting and repair procedures An Appendix at the end of the manual provides additional information for the owner Throughout this manual console keypad keystrokes are enclosed in The names of the keys and special console operational modes are shown in capital letters For example your machine is ready to use when the console is in the ATTRACT mode Press MANUAL to start the MANUAL exercise program WHAT IS THE STAIRMASTER FREECLIMBER EXERCISE SYSTEM The StairMaster FreeClimber exercise systems are vertical climbing machines with an independent step action The independent step action combined with the patented pedal geometry featured on all StairMaster steppers provides an aerobic workout equivalent to uphill running or climbing stairs but without the high impact pounding to thejoints and muscles There are five FreeClimber models the 4600 PT Personal Trainer the 4600 CL Cord Less the 4400 PT the 4400 CL and the 4200 PT All FreeClimbers feature the Quiet Drive transmission The 4600 PT and the 4600 CL have an adjustable tilting full featured console with a Light Emitting Diode LED display The 4400 PT and the 4400 CL have an upright rail less design The 4600 PT and the 4400 PT use an external power supply that is plugged into an AC wall outle
67. t 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 The heart rate receiverjack should point down Ensure that the heart rate receiver is connected to the console and that the connection is not loose If possible swap the heart rate receiver with one from another machine Ifthe problem still exists contact the Customer Service Department at 800 331 3578 Page 44 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 prob lem in the drive train Attempt to isolate the problem area by performing the fol lowing 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 TO REDUCE THE RISK OF INJURY DO NOT OPERATE THE MACHINE WHILE THE COVERS ARE REMOVED DO NOT DEPRESS OR RAISE THE PEDALS WHILE 5 HANDS ARE INSIDE THE MACHINE 2 Noise can be generated by a Poly V or HTD belt that is either too tight or too loose Check the condition and the tension of the belts Replace worn belts Adjust the
68. to make sure you are satisfied FACTORY TRAINED SERVICE NETWORK The StairMaster service staff is on call to quickly address any product concerns Service isjust a toll free call away FACTORY DIRECT PRICES No warehousing fee No retail markup StairMaster sells directly to you for the best prices available AFFORDABLE LEASING PROGRAM We help you make the most of your money with several types of leasing programs available FACILITY PLANNING Cordless units Space efficient designs Exciting facility layout plans Our staff works closely with you to maximize the equipment layout of your club or fitness area PRE ASSEMBLED DELIVERY No set up no hassle MARKETING SUPPORT Lots of sizzle with StairMaster product catalogs posters promotional kits and seasonal promotions Pageiv STAIRCLIMBERS The Best in the Industry Our popular FreeClimber stairclimber line now offers you 5 different models to choose from These models include the new fully featured FreeClimber 4600 PT and the cordless FreeClimber 4600 CL along with the FreeCl imber 4400 PT and the cordless FreeClimber 4400 CL with Polar Heart Rate Monitor and the cost efficient FreeClimber 4200 PT all designed especially for health clubs Other StairMaster stairclimbers include the Stepmill 7000 PT for the most challenging stairclimbing workout as well as the legendary StairMaster 4000 ELLIPTICAL STRIDING SYSTEMS The New StairMa
69. uld be displayed corresponds to the MANUAL program Press SELECT The arrow pointing to the word Weight will flash and 150 is displayed Use the or ARROW to adjust your body weight Press ENTER SELECT when it is correct The arrow pointing to Speed Level will flash and 3 is displayed Press SELECT The arrow pointing to the word Time will flash and the number 15 is displayed Press ARROW to change the workout time to 10 minutes Press SELECT Begin Exercising 1 Take deep comfortable steps Do not let the pedals touch the floor or contact the upper stop When you begin to exercise the MANUAL program starts at level three As you become comfortable with exercise motion press INCREASE and DECREASE to adjust your climbing speed Relax and stand up straight while exercising Use the handlebars for balance see Figure 5 Page 11 BASIC OPERATING INSTRUCTIONS 4 one 22457247 35 ROIS 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 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 The console retums to the ATIRACT mode if you rest longer than the allotted rest
70. ute Removes the audio sound from the headphones Channel 1 Changes commercial entertainment system channels EXERCISE PROGRAM KEYPAD The purple exercise keypad is located below the display and to the left of the function keypad While the console is in the ATTRACT mode press one of the exercise program keys to preview the desired workout The sequence of prompts for the preset exercise programs is slightly different than the sequence described earlier for the MANUAL program After you press one of the exercise program keys the exercise program profile is scrolled across the display Page 18 VE EA SN Y AS 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 The Quick Start Option You can quickly start any workout on the 4600 4400 PT CL by first pressing one ofthe purple exercise program keys and then pressing ENTER twice On the 4600 PT CL you can alsojust press the QUICKSTART program key to begin exercising You do not have to enter any other information The length of the workout is set automatically and vari
71. variable resistance line from StairMaster that are available with either an upright or recumbent seat Just like StairMaster s legend ary stairclimbers Stratus exercise bikes are very different from other models simply because they feel so good to use 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 Both products feature an easy to operate first time user option as well as a quick start feature STAIRMASTER STRENGTH SYSTEMS Feel the Difference Club members will feel the difference the first time they use StairMaster strength equipment designed to work the way your body works Consisting of the Gravitron 2000 AT and the new Arcuate and Linear lines StairMaster offers you 17 different strength training products to choose from To ensure the highest quality all StairMaster strength equipment is now manufactured at our own factory in Tulsa Oklahoma Page vii WARRANTY This isto 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
72. ver Charge the battery for approximately 24 48 hours and then recheck it It is okay to use machine while the battery charger is connected Battery Disposal When ordering new batteries you will need to properly dispose of recycle your old lead acid batteries Most federal and state regulations require lead acid batteries be recycled Do not throwaway old batteries Lead is atoxic heavy metal hazardous to living organisms Disposal instructions and a list of recycling centers are tabulated in the Appendix If you have questions contact the Customer Service Department at 800 331 3578 Page 35 MAINTENANCE INSTRUCTIONS Table 5 Recommended Preventive Maintenance Schedule RECCOMENDED Drive and Step Chains Step Chain Connection Points Pedal Shafts amp Leveling Arm Pins Pedal Arm Retum Springs Pedal Arm Shafts Battery Clean and inspect Lubricate Diluted house hold cleaner Each week or after 70 hours 30W motor oil Remove clean and lubricate Clean and lubricate Clean and lubricate Clean and lubricate Inspect and wipe down Clean and lubricate Check Voltage Inspect amp adjust tension Every 3 months or 900 hours Degreaser Every 3 months or 900 hours Clean dry rag Every 3 months or 900 hours Clean dry ra Clean dry ra Clean dry ra Every 3 months or 900 hours Each week or after 70 hours Every 3 months or 9
73. verse the removal instructions to reinstall the leveling arm Page 56 PEDAL 1 Remove the pedal and the bottom cover 2 Remove the step chain retainers 3 Support the pedal arm Unhook the pedal arm retum 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 IN WARNING TO REDUCE THE RISK OF EYE INJURY WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS 6 Slide or gently tap the pedal arm off the mounting shaft T Clean the pedal arm shaft and leveling arm pin with a cloth dampened with 30W motor oil before reassembly 8 Reverse the removal procedures to reinstall the pedal arm PEDAL PAD 1 The pedal pad wraps around the pedal and locks into place under the pedal Separate the pedal pad from the pedal by grabbing the bottom of the pedal and pulling down and out 2 Lift the other side of the pedal pad up and remove the pedal pad from the pedal Note There is a right and left pedal pad Do not install a left pedal padon a right pedal ora right pedal padon a left pedal Page 57 ECCENTRIC HUB ASSEMBLY 1 2 Remove the bottom cover Remove the Poly V and HTD belts Loosen and remove the four nyloc nuts and bolts from the hub Remove the assembly from the frame Reassem
74. within 396 of the medical standard but its ability to detect a heart rate signal is influenced by several factors Movement of the muscles of the upper body produces an electrical signal that will interfere with the detection of the heart rate signal by the sensors Movement of the hands whi le they are in contact with the sensors also produces interference Calluses and hand lotion act as an insulating layer to reduce the signal strength Also the EKG signal generated by some individuals is not strong enough to be detected by the sensors Typically these individuals account for 5 7 of the population Most people between 93 95 will not have a problem with the system provided interference from movement is minimal Lightly grip the sensors with each hand The heart rate display is shown automatically in the upper window the first time the sensors are touched A valid signal is shown by a pulsating heart icon and the number of beats per minute next to the word Pulse The heart icon will stop beating and two dashes replace the numbers when the sensors are released or an invalid signal is received Page 13 POLAR HEART RATE 4600 4400 The StairMaster FreeClimber 460014400 PT ICL 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 Y
75. y or the equipment shall be put out of use until it is repaired Failure to follow all guidelines may compromise the effectiveness of the exercise experience expose yourself and possibly others to injury and reduce the longevity of the machine Follow all training instructions listed in the manual and or on the machine Physical injury may result from incorrect or excessive training SAVE THESE INSTRUCTIONS Page 2 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 Console Reading Rack Handles Pivoti Console Mount Left Handrail Bottom Cover LeftPedal Transport Wheel SIDE VIEW Figure 1 Major Parts 4600 Page 3 INTRODUCTION andlebars Top cover Mid cover pedal Figure 2 Major Parts 4400 PT eL 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 tile front of the machine The dimensions and general specifications of the machines are listed in Table 1 Table 1 Dimensions and Specifications for the StairMaster FreeClimber Exercise Systems Physical Dimensions Length Width at Front Leg 4400 PT CL 4200 DII

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