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1. 28 LIST OF WIRING DIAGRAMS Wiring Diagram 1 Wall Mounted Power SUPPIY E RET 75 Wiring Diagram 2 Main Cable Assembly 76 Wiring Diagram 3 Serial Cable Assembly 77 Wiring Diagram 4 8 78 Page viii SAFETY GUIDELINES IMPORTANT SAFETY INSTRUCTIONS ELECTRICAL GUIDELINES FOR SAFELY OPERATING THE STAIRMASTER SPINNAKER SYSTEMS CYCLE ERGOMETER When using any electrical equipment several basic precautionary guidelines should always be strictly enforced Among the safety precautions to which you should adhere when operating the Spinnaker systems cycle ergometer are the following Read all instructions thoroughly before using the StairMaster Spinnaker systems cycle ergometer 2 To reduce the risk of electric shock 3 Ton Always unplug the machine from the electrical outlet before cleaning performing maintenance or making repairs educe the risk of burns fire electric shock or injury to individuals Always unplug the power supply from the outlet before putting on or taking off parts Never attempt any adjustments or repairs while someone is exercising on the machine Closely super
2. 11 Figure Spinnaker Systems Console Power Test 18 Figure 4 Spinnaker Systems Console Group Race 18 Figures Leveling Adjustment 58 Figure Power Supplies 59 Figure 7 Cover Fastener Location 3000 CE KE e Figure 8 Cover Fastener Location 3600 RC 2 ETIN D 9 62 Figure 10 Right Side View MEET M idi 63 Eb View JODU GE le al iki 64 Sc 2 c Plgnt ode E E 65 Figure 13 Left Side View 3000 ee 66 Figure 14 Seat Adjustment Pin Assembly 3000 67 Figure 15 Seat Assembly 3600 8 68 Hour T6 pg 90170227 7 69 Fan EE 70 Howe TE E 71 Figure 19 Intermediate Shaft Assembly 6 72 Figure E E 73 Figure 21 Fan Shaft Assembly Cross Section c 74 Figure 22 55 LIST OF TABLES Teble1 Language Codes asli esirin 7 apio tee 8 LG 655 il 16 aa E 23 Page vii 5 Console C008 es mize rss Deb recta cur __ Table 6 Preventive Maintenance
3. THIS TEST IS VERY STRENUOUS AND REQUIRES A GREAT DEAL OF EFFORT TO AVOID BODILY INJURY CONSULT A PHYSICIAN BEFORE TAKING THIS TEST IF YOU ARE CONCERNED ABOUT YOUR ABILITY TO PERFORM THIS TEST The message GO will appear in the text bar to prompt you to begin the test sighting the prompt pedal as fast as you can for the entire 30 second period During the test your power output will be shown in two ways on the display screen numerically in watts and graphically as a power curve refer to Figure 3 The dots under the power curve light up as you pedal faster During the test the objective is to pedal as fast as vou can for as long as you can The te text bar shows the time left in e eg T mne Your test results are displayed during the fieri cool down phase Your power output over the 30 second test period are shown in the display as a graph and in the text bar in three ways peak power peak power per kilogram of body mass and average power Your average power per kilogram of body mass is compared to normative values for others of your age and gender Your results are then stored in the console until the next exercise program is started To review the results of your test press WORKOUT STATS 4 The INTERVAL programs vary the ratio of easy pedaling and fast pedaling based on a 15 second interval continuously throughout the duration of the program INTERVAL ONE uses three periods of easy peda
4. only and the side covers Remove the drive chain Remove the left pedal Loosen and remove the bottom bracket jam nut located on the left side of the crank refer to Figure 20 This nut has reverse threads loosen it by turning it clockwise Remove the round plastic crank shield from the left side of the crank Remove the bearing clamps by loosening the allen bolts from the left side clamp Loosen and remove the left bearing nut assembly This nut has reverse threads loosen it by turning it clockwise Slide the crank out of the frame to the right The right bearing nut assembly can be removed from the crank with a 32 mm cone wrench The right bearing nut assembly also holds the chainring in place on the crank If the chainring is damaged replace it now Inspect the bearings for smoothness of operation Replace the bearings if necessary Ensure that the right bearing nut assembly is tight against the chainring before reinstalling the crank into the frame Page 53 16 PARTS REMOVAL AND REPLACEMENT 12 Install the left bearing nut assembly onto the crank and tighten it with a wrench set to 22 inch pounds 2 5 Newton meters Do not overtighten the nut the crank should spin freely Install both bearing clamps and tighten the allen bolts Do not overtighten the allen bolts the crank should spin freely Install the round plastic crank shield the jam nut and the pedal onto the left side of the crank Remem
5. 2 16 48 1 8 FIGURES Figure 16 Drive Chain Tension Page 69 FIGURES URS A V Su Figure 17 Fan Shaft Assembly N NA 55 lt 63 Threaded Spacer Holl Effect Sensor Mognet Mount Screw 2X NC Fon shoft brocket 2x See detail A Flange mounted Flot Wosher 2X bearing 2x DETAIL right amp left side fon shoft brocket 90030 C 3 02 98 1 70 FIGURES 3 2 2 16 95 ne Page 71 FIGURES Figure 19 Intermediate Shaft Assembly 74 Wave Washer Bearing 03 Poly V Pulley Bearing 09 77 N intermediate 007 Freewheel 2 ndm gu Sprocket 49 Intermediate Shaft Bracket 90032 3 02 95 1 17 FIGURES amp Figure 20 Crank Assembly Clamp 2X Crank Shield B 2 M Z N a que Lock Washer 2 6 gt Screw 69d qe 90033 8 3 02 95 1912 Page 73 Figure 21 Fan Shaft Assembly Cross Section Fiywheel Fonshoft Threoded Spocer Fon Flonge Mounted Beoring Holl Effect Sensor Fanshoft Brocket Page 74 WIRING DIAGRAMS Wiring Diagram 1 Wall Mounted Power Supply 90016 8 3 02 95 1 2 WIRING DIAGRAMS Wiring Diagram 2 Main Cable Assembly 5 VIEW WIRE INSULATION
6. Page 42 Remove the neck covers 3000 CE only and the side covers Examine the area around the chain crank and pedals for anything out of the ordinary Slowly turn the crank and see if there are any obstructions in the drive train area Hold one crank arm in each hand Rock the crank back and forth to detect excess play or looseness in the crank bearings Readjust the bearing nut assemblies and tighten the bearing clamps if necessary Turn the cranks and listen for the noise If the noise is still present go to step 3 If you do not hear the noise the cranks or the pedals were hitting the covers Examine the side covers near the crank cutout for evidence of wear Verify that both crank arms are straight When you reinstall the side covers make sure all fasteners are properly installed TROUBLESHOOTING THE DRIVE TRAIN Remove the drive chain Spin the crank If the noise is still present go to step 4 If you do not hear the noise reinstall the drive chain and check the chain alignment between the chainring and the freewheel If the noise is still present and the drive chain is properly aligned replace the drive chain Remove both pedals from the crank Spin the crank If the noise is still present go to step 5 If you do not hear the noise the pedal spindle bearings may be worn out To check the bearings hold a pedal in one hand and rotate the pedal spindle with the other hand If the spindle is hard to turn or if you
7. Page 3 INSTALLATION INSTRUCTIONS Refer to the Grounding Instructions section of this Manual if the wall outlet does not accept a three prong plug If you do not have the correct power supply contact the Customer Service Department of StairMaster Sports Medical Products Inc at 800 331 3578 to order the correct power supply before proceeding International customers may contact their local distributor Single use power supply configuration United States Canada and Japan If you have a single Spinnaker systems cycle ergometer or if you have more than one Spinnaker systems cycle ergometer but do not want to connect your machines together for group racing perform the following instructions to connect power to each Spinnaker systems cycle ergometer f you have more than one Spinnaker systems cycle ergometer and want to use the group race and team race features go to step 4 If you have a single Spinnaker systems cycle ergometer that will be operated outside the United States Canada or Japan go to step 5 Plug the power supply into the AC wall outlet Connect the DC power cable from the power supply to the power connector located just inside the right or left side cover of your machine refer to Figure 7 or 8 Ensure the power connector cap is installed on the power connector that is not in use Observe the console It should emit tone scroll a software revision level message across the text bar and displ
8. Spinnaker Systems Owner s Manual SPORTS MEDICAL PRODUCTS INC Printed in the United States 1995 StairMaster Sports Medical Products Inc All rights reserved Corporate Headquarters 12421 Willows Road N E Suite 100 Kirkland WA 98034 800 635 2936 206 823 1825 Fax 206 823 9490 SPORTS MEDICAL PRODUCTS INC P N 24255 A 1995 StairMaster Sports Medical Products Inc StairMaster StalMaster Spinnaker 3000 CE and 3600 RC are trademarks of StairMaster Sports Medical Products Inc Page iii This is to certify that the StairMaster Spinnaker systems cycle ergometer is warrant for a period of one year by StairMaster Sports Medical Products Inc to be free of all defects in materials and workmanship This warranty does not apply to any defect caused by negligence misuse accident alteration improper maintenance or an act of God This warranty is nontransferable from the original owner If within one year from date of purchase the StairMaster Spinnaker systems cycle ergometer should fail to operate properly contact the Customer Service Department of StairMaster Sports Medical Products Inc to report the problem International customers may contact their local distributor When calling please be prepared to provide our customer service representative with the following information Your name shipping address and telephone number The model number of the inoper
9. ACTUAL to the pedal rate you need to maintain to keep pace with the program TARGET For example the default display for the INTERVAL ONE program is pedal rate Reading from left to right the text bar would show the pedal rate of the user at that particular instant ACTUALJ the units in this case RPM the pedal rate you need to maintain to keep pace with the program TARGET and the time in seconds remaining in the current interval TIME DISPLAY The display provides a graphical depiction of your actual pedal rate compared to the target pedaling rate set by the pacer The display graphics are slightly different for each program refer to the program descriptions in the Exercise Program Keypad section of this Manual for more details FUNCTION KEYPAD e The function keypad is located on the right side of the console Ten of the keys on the keypad have two pieces of information on them a number and a workout statistic Before the exercise program begins the numbers are used to enter data in response to the console prompts During or immediately after the exercise program the function keypad keys are used to recall workout statistics which are then displayed on the text bar 1 PEDAL RATE is the number of pedal revolutions per minute also referred to as cycling cadence During an exercise program this button displays the cycling cadence at that particular moment in time After you have completed your exercise program the averag
10. Electrical Guidelines for Safely Operating the Spinnaker Systems Cycle Ergometer 1 ISIABATIONC INSTRUCTIONS aede ue 3 Physical Dimensions and Electrical Specifications of the Spinnaker Systems Cycle Ergometer 7 BASIC OPERATING 9 LE 9 Tha ATIBACT r SRMN PM MM BUR E EEE ag 10 Tie BASIC EXENASE POG 10 EE 11 ge seq 12 DISDEN TSA PPEP 12 12 SSS 14 Customizing the Text Bar Scrolling Message 1 ee 22 the Meester ikimizin 22 Codes for the Spinnaker Systems Console 24 MAINTENANCE INSTRUCTIONS SL aaa hPa Re Eae 25 e a MEMO NESE 25 11211217 e e on 25 Maintenance Records brote Ue M 25 Initial Service MEE RINT REIR ARR 26 Preventive Maintenance E TROUBLESHOOTING GUIDELINES IE ESTEE TOP 29
11. In addition to the BASIC EXERCISE program there are nine other exercise programs on the Spinnaker systems cycle ergometer Detailed descriptions of each of these programs are presented in the next section of this Manual Page 10 BT ae Figure 1 Spinnaker Systems Console Basic Exercise Program Text bar ca fo muran Pa ics a ads pope D LL dii he dm w mr sa fo Function Display Figure 2 Spinnaker Systems Console Page 11 SPINNAKER SYSTEMS CONSOLE The StairMaster Spinnaker systems console is divided into four sections the text the display the function keypad and the exercise program keypad refer to Figure 2 TEXT BAR Information regarding workout statistics and data entry is displayed or scrolled across the text bar There are five words under the text bar that are only visible when lit from behind an arrangement which is called a deadfront The deadfronts are used in conjunction with the text displayed in the text bar Reading from left to right the deadfronts are ACTUAL BEHIND AHEAD TARGET and TIME The ACTUAL TARGET and TIME deadfronts are lit at certain times during the course of most exercise programs The feedback in the text bar is lined up above the deadfronts The ACTUAL and TARGET deadfronts are used to compare your pedal rate
12. link retaining plate is facing the direction of chain travel Check the tension in the drive chain There should be 1 2 1 cm of up and down travel for a total of 1 2 cm the middle of the lower section of the drive chain refer to Figure 16 To adjust the chain tension loosen the nuts at the top and the bottom of the intermediate shaft bracket Pivot the brackets as needed to get the proper chain tension Tighten the nuts and recheck the chain tension Readjust the chain if necessary Reinstall the covers PARTS REMOVAL AND REPLACEMENT Remove both neck covers 3000 CE only and the side covers The fan is attached to the fan shaft with an allen head set screw Slowly spin the fans and find the small cutout located along the outside edge of the fan directly above the set screw Use a T handled allen wrench to loosen the set screw Slide the fan off the fan shaft Reverse the steps to reinstall the fan Make sure the set screw in the fan bushing makes contact with the flat section of the fan shaft If you remove both fans remember that the larger diameter fan goes on the right side of the fan shaft The fan blades should be facing the direction of rotation The fans are marked with directional arrows INTERMEDIATE SHAFT ASSEMBLY POLY V BELT POLY V PULLEY FREEWHEEL 1 2 10 Remove both neck covers 3000 CE only and the side covers Remove both fans Remove the drive chain Loosen but do not rem
13. Cover EE Frame Tube Fastener Removal 99 Fastener Removal Too e 90117 3 02 95 1 2 Figure 10 Right Side View 3000 Reading rack r6 Bolt 2x 7 Flot washer 4x 8 Nyloc nut 2x Freewhee 90029 C 3 02 95 1412 Page 63 FIGURES Magnet Mount Fan Shaft Brocket Poly V pulley Poly V belt 5 18 Footstrop 19 Pedol 90026 C 2 16 95 1812 FIGURES Figure 12 Right Side View 3600 RC 90113 3 02 95 1 18 Page 65 Figure 13 Left Side View 3600 RC Screw 4x Lock Wosher 4x 4 Cap 4x 5 Washer 4x Flat Washer 8 Nut 2x 29 Ny oc Nut 4x PN 65 usss y we he x fr Tr Screw 4x crew 9 Trock 7 Sprocket 3t Washer x Guard 3 2 Screw 2x 1 31 Belt Nyloc Nut 2 353 XA Mes ia 2 Nut 8 54 Grommet Flat Washer G gt 90114 5 02 99 1 20 FIGURES Figure 14 Seat Adjustment Pin Assembly 3000 CE Sec ERAS an 1 an 4X kV 4X Page 67 FIGURES Figure 15 Seat Assembly 3600 RC 49 Mid Bock Seot Mid Back 5 Seat ack 5 69 Seot Bottom Cop Bx Screw Bx Wosher 8 63 Flot Wosher 6 Lock Wosher 4x 40 Adjustment Lever 56 Screw 4x 90115
14. INSTALLATION INSTRUCTIONS Table 2 Specifications of the Spinnaker Systems Cycle Ergometer Dimensions 3000 3600 RC 46 inches 117 cm 62 inches 157 cm Length Width at the base 19 inches 48 cm 19 inches 48 cm handlebars 22 inches 56 cm 22 inches 56 cm Height at the handlebars 57 inches 145 cm 42 inches 107 cm Weight 125 pounds 57 kg 150 pounds 68 kg Power Supply Characteristics Wall mount unit WP 1 input voltage 110 120 VAC 50 60 Hz 110 120 VAC 50 60 Hz output voltage 9 15 VDC 9 15 VDC output current 085 Amp 085 Amp input power consumption 15 Watts 15 Watts Optional power supply PS 6 input voltage 110 120 VAC 50 60 Hz 110 120 VAC 50 60 Hz output voltage 10 16 vdc 10 16 vdc maximum output current 2 5 Amps 2 5 Amps input power consumption 60 Watts 60 Watts Optional power supplies intended for use outside the United States Canada and Japan are available for 220 240 VAC 50 60 Hz power requirements These power supplies have not been evaluated by Underwriters Laboratories Inc BASIC OPERATING INSTRUCTIONS Que You should check two adjustments before using your StairMaster Spinnaker systems cycle ergometer the seat height and the pedal footstrap length Seat Height Adjustment on the 5 3000 Cycle Ergometer Sit on the seat Put both feet onto the pedals and into the footstraps Pedal slowly and then stop when one leg is extended and your foot is as
15. Keep the power supply cord and the DC cable away from heated surfaces Never drop or insert any object into any opening on the machine except when lubricating the chain Do not use the machine outdoors Do not operate where aerosol spray products are being used or where oxygen is being administered To disconnect the machine remove the wall mounted power supply or the AC power cord plug if applicable from the AC wall outlet 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 SAVE THESE INSTRUCTIONS INSTALLATION INSTRUCTIONS leaving the StairMaster manufacturing facility Tulsa Oklahoma your tairMaster Spinnaker systems cycle ergometer was thoroughly inspected and tested to ensure that it operates properly To minimize damage while in transit your machine was carefully prepared for shipment To transport your Spinnaker systems cycle ergometer into a building a doorway width of at least 22 inches 56 cm is required Once inside the machine should be placed on a solid level surface near an AC wall outlet 120 volts are required for Spinnaker systems cycle ergometers in the United States Canada and Japan Before your Spinnaker systems cycle ergometer is ready to use it will require minor assembly 1 Spinnaker systems cycle ergometer has four leveling adjustment
16. MESSAGE e The message that scrolls across 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 Encode your message using the character codes listed in Table 4 2 While the console is in the ATTRACT mode press UP ARROW 7 6 0 7 ENTER 3 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 4 For example to program the message EXERCISE IS FUN press UP ARROW 7 6 0 7 ENTER Then press 1 5 3 4 1 5 2 8 1 1 9 2 9 1 5 1 0 1 9 12 9 1 0 1 6 3 1 2 4 ENTER At that point your message will begin scrolling The console is again in the ATTRACT mode 5 If you make a mistake while entering the codes press CLEAR to erase the last character entered EDITING THE SCROLLING MESSAGE 1 While the console is in the ATTRACT mode press UP ARROW 7 6 0 7 ENTER to display the first character of the message onto the text bar 2 Press the UP ARROW and DOWN ARROW to scroll through the message by character 3 Press CLEAR to delete the last character displayed on the text bar Press ENTER to end the editing process 4 To edi
17. NO to deactivate the draft mode When the drafting mode is on the leading bike must overcome a certain amount of wind resistance while the bikes following the lead Page 20 SPINNAKER SYSTEMS CONSOLE e bike have the advantage of riding in the lead bike s slipstream The trailing bikes must stay within two dots of the bike ahead of them to stay in the draft The drafting mode is much like handicapping the strongest rider while introducing realistic bicycle racing strategy When the drafting mode is on sometimes it is the smartest rather than the strongest rider who wins the race When the drafting mode is off all participants are an even competitive footing Select the race distance by pressing a number key and then ENTER A five mile race requires all participants to complete five one mile laps After the race is set up the person in charge must press ENTER All bike s text bars will then show a five second countdown to the start of the race The display for the GROUP RACE is a series of five two lap lanes refer to Figure 4 Each lane is separated by a row of lighted dots The two ends of your bike s lane are enclosed by two lit dots The enclosure dots at the right end of your lane will disappear once the race starts A single enclosure dot remains lit at the left end to indicate your lane On the first lap of the race your bike is shown as a single dot traveling from left to right across the display When your b
18. O kg 1 min Page 13 10 11 12 13 14 15 16 SPINNAKER SYSTEMS CONSOLE During the exercise program this button displays the MET level at which you amp currently exercising After you have completed your exercise program the average MET level during your workout is displayed TOTAL WORK provides a cumulative total of the amount of work performed during a workout Work is expressed in kilogram meters A kilogram meter kgm is the amount of force necessary to move a one kilogram mass 2 2 pounds one vertical meter 3 3 feet Since work is quantity the total amount of work increases with time The DISPLAY button allows you to return the text bar graphics to the default display for that program On most exercise programs the default display is PEDAL RATE The WORKOUT STATS button continuously scrolls the information on all nine performance feedback buttons across the text bar This information can be displayed at any time during a workout It is also stored the console memory until the next exercise program is started You can press any function keypad button during the scrolling summary and stop at that statistic You have 10 seconds to press another function keypad button before the summary ends The UP and DOWN ARROWS increase or decrease respectively the exercise intensity level of the INTERVAL programs The exercise intensity level ranges from 1 the easiest to 20 the most difficul
19. Refer to the Parts Removal and Replacement section of this Manual for any disassembly and assembly instructions To order a replacement part or to get help with the troubleshooting process contact the Customer Service Department of StairMaster Sports Medical Products Inc 1 Symptom squealing whining noise is heard whenever the fans are spinning the noise is heard whether the cranks are turning or not This noise is caused by a loose Poly V belt or seized bearings in either the fan shaft or the intermediate shaft 1 Remove the neck covers 3000 CE only and the side covers Check the Poly V belt for proper tension If necessary tighten the belt according to the procedure outlined in the Poly V Belt section of this Manual If the Poly V belt is properly tensioned you will need to check the shaft bearings Watch the fan and intermediate shafts The noise may be in sync with the revolutions of one of the shafts The fan shaft spins at a faster rate than the intermediate shaft You may be able to isolate the problem by observing how often the noise occurs Check the bearings in the noisy shaft and replace if necessary If the noise cannot be isolated in this manner start by removing and checking the intermediate shaft bearings and then the fan shaft bearings e Il Symptom A clunking or clicking noise is heard when the pedals are turned but not when you stop pedaling This indicates a problem in the pedal crank area 1
20. V belt Screw 5 16 18 x 2 3 4 loc nut 5 16 rommet 1 1 2 O D 7 o 33 34 k rae s ee SENE pe d e 5222 252 WER e aa RERO WEN Ed n Wu SSS NE F 5 24075 21414 8 KEY TO FIGURES AND WIRING DIAGRAMS 3 Description Flat washer Bolt 3 8 16 x3 Seat track Seat 3000 CE Bolt 5 16 18x 1 Lock washer 5 16 Seat post assembi Seat tube cap Screw 98 x 3 8 Grommet seat post Seat adjustment knob assembi Seat back cover 47 Back seat 3600 RC Cap seat frame Mid back seat 3600 RC Bottom seat 3600 RC Mid back seat cover 2 Screw 5 16 18 x 2 1 4 Finishing washer 312 Flat washer 5 16 Tapered handle djustment lever Tile mn mi e an right side an left side 2072 olt 3 8 16 3 4 olt 3 8 16x 1 1 2 readed spacer an shaft Fan shaft bracket Screw 3 8 16 x 1 7 Lock washer 3 8 Jam nut 3 8 16 Flange mounted bearing J bolt 3000 CE J bolt 3600 RC Spring retainer Valve spring Sau l Row ri SN TN S em 0 2 key wj 72 KEY TO FIGURES AN
21. circuit and has a grounding plug that looks like the plug illustrated in sketch A in Figure 16 A temporary adapter that looks like the adapter illustrated in sketches B and C may be used to connect this plug to a two pole receptacle as shown in sketch B if a properly grounded outlet is not available The temporary adapter should be used only until a properly grounded outlet sketch A can be installed by a qualified electrician The green colored lug extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box cover Whenever an adapter is used it must be held in place by a metal screw This may vary for International power supplies EN 25 27 gt AZ P 9 e y Figure 22 Grounding Systems NOTICE FCC COMPLIANCE This equipment has been tested and found to comply with the limits for a Class A device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of equipment in a residential area may cause harmful interference in which case the user will be required
22. deadfront You can change the text bar feedback by pressing the appropriate function keypad button during the workout As your dots travel around the display perimeter the finish line for that interval will light up with one lap to go The finish line may be anywhere around the perimeter but when it shows up it always signifies that there is one lap to go The goal is to tie or beat the pacer to the finish line The AHEAD deadfront will briefly flash if you beat or tie the pacer to the finish line The BEHIND deadfront will flash if the pacer beat you to the finish line You should coo down at the slow pedaling rate for one minute at the end of the exercise program The pacer dot will disappear signifying the cool down period Your workout stats are scrolled across the text bar after the cool down period A recommended intensity level for your next workout based on the number of times you at least tied the pacer to the finish line will also be shown in the text bar Your results are stored in the console until the next exercise program is started To review the results of your performance you can press WORKOUT STATS SPINNAKER SYSTEMS CONSOLE BEG6SeEee6 0 1 0009 Figure 4 Spinnaker Systems Console Group Race Page 18 SPINNAKER SYSTEMS CONSOLE OG The TEAM RACE TIME TRIAL is a four bike race with two bikes per team During the race teammates can draft each other While drafting the lead bike must over
23. line voltage is within range Replace the cord if the voltage is not within the specified range and then test the new cord Reconnect the AC power cord to the power supply and proceed to section C C Verify DC power 1 Make sure that the AC power cord is properly connected to the power supply and that the AC wall outlet is delivering the proper voltage Turn on the power supply The indicator light on the front panel should be lit If it is proceed to step 3 If the indicator is not lit when the switch is on reset the circuit breaker If the light is still not lit replace the power supply and test the new power supply ELECTRICAL TROUBLESHOOTING IPS 3 POWER SUPPLY Disconnect the DC cable from the power supply Use a DC voltmeter to verify the DC power at the DC connector on the power supply front panel refer to Wiring Diagram 5 Pin 1 is positive and 2 is negative The voltage should range between 10 and 16 VDC If it does go to step 4 Replace the power supply if the DC voltage is not within the specified range and test the new power supply Reconnect the DC cable to the power supply front panel Disconnect the cable from the DC power connector located just inside the side cover Use DC voltmeter to verify 10 16 VDC at this end of the cable Pin 1 is positive and pin 2 is negative refer to Wiring Diagram 5 If the VDC is within range go to step 5 Replace the DC cable if the VDC is outside th
24. near zero ohms the cable is good and you should proceed to step 4 If continuity does not exist through the main cable replace the cable 4 Plug the power supply into the AC wall outlet Reconnect the plastic connector at the hall effect sensor and the main cable wire junction Check the power at the connector by inserting the voltmeter probes into the connector at the hall effect sensor side at pin 1 the black wire is negative and pin 44 the red wire is positive refer to Wiring Diagram 2 The reading should be between 4 8 and 5 2 VDC If the reading is withj the specified range replace either the console or the hall effect sens the reading is outside the recommended range replace the hall effect sensor Page 34 ELECTRICAL TROUBLESHOOTING SERIALLY LINKED SPINNAKERS 8 Spinnaker Systems Cycle Ergometers Serially Linked For The Group Racing Option Symptom One or more Spinnaker systems cycle ergometer does not power up These power tests will also work on serially linked Spinnaker cycle ergometers which are operated outside the United States Canada and Japan Perform a visual check Check the following things first 1 2 Is the power supply plugged in Is the green light lit on the power supply If the light is not on is the power supply switched on and or does the circuit breaker need to be reset Are all the cables power and serial properly connected to the power supply and
25. of the bikes during the group race These address numbers range from 1 to 5 Each bike must have a unique number within this range During the group race the bike with the address 1 will be displayed in the top lane the bike with the address 2 will be displayed in the next lane down and so on with the 5 bike in the bottom lane Press UP ARROW 1 7 4 6 ENTER on the first bike s console The console will prompt you to enter the bike number Press 1 ENTER Go to the next Spinnaker systems cycle ergometer in line Press UP ARROW 1 7 4 6 ENTER this console Press 2 Page 5 INSTALLATION INSTRUCTIONS ENTER for this bike Set up the remaining bikes until all bikes have unique address from 1 to 5 Go to step 6 5 The International power supply configuration International 220 240 VAC To connect power to a single Spinnaker systems cycle ergometer in countries other than the United States Canada or Japan perform the following steps Ensure that the input AC power rating marked on the power supply matches the available power If you do not have the correct power supply contact the local StairMaster Sports Medical Products Inc distributor to order the correct power supply before proceeding A WARNING TO REDUCE RISK OF ELECTRICAL SHOCK FIRE 00 NOT CONNECT MORE THAN FIVE 5 SPINNAKER SYSTEMS CYCLE ERGOMETERS TO THE IPS 3 MODEL POWER SUPPLY USE ONLY T
26. 19 SPINNAKER SYSTEMS CONSOLE Your team s elapsed time for the race is the finishing time of your M second place rider In other words your team is only as fast as the slowest rider Your team s standing in the race and your elapsed time are shown in the text bar after you have completed the race You also have access to all other workout stats except MET Level The race results are stored in the console until the next exercise program is started You can press WORKOUT STATS to review the results of your performance 6 The ROAD RACE is a race against a computer opponent You will be prompted to enter your body weight and the desired pace of the race You have the choice between a variable pace or a steady pace race If you choose the variable pace the race is subdivided into three basic sections The computer starts with a short warm up the middle section is a slowly changing series of fast and slow intervals and the end of the race finishes with a fast sprint If you selected the steady pace race the pace does not change over the course of the race The average speed of either race mode is still controlled by the pace you select Finally you are required to enter the distance of the race Once you enter the distance your five second countdown to the start will appear in the text bar The display is equivalent to 1 4 mile race track You are represented as two dots in the outer lane The computer pacer is the single dot in the i
27. 49 2204 628 90 HEADQUARTERS 44 908 221 323 FAX 44 908 223 162 FRANCE BELGIUM MONDIAL S PR L 32 82 226775 FAX 32 82 226854 COUNTRIES NOT LISTED 206 823 1825 FAX 206 823 7505 CANADA TRC SPORTS SYSTEMS 800 668 4857 905 712 2719 FAX 905 712 3722 JAPAN SENOH CORPORATION 81 035479 6711 FAX 81 035479 6703 AUSTRALIA THE FITNESS GENERATION PTY LTD 61 3 800 2122 FAX 61 3 800 2722 SWEDEN NORWAY NORDIC GYM PRODUCTION 46 278 242 10 FAX 46 278 159 66 FIGURES Figure 5 Leveling Adjustment Cap Page 58 NS N 16 N rd 4 e Ee ee FIGURES Figure 6 Power Supplies H Y Woll mounted power supply bike power supply domestic 5 6 International power supply 5 3 90031 c Am 1 FIGURES Figure 7 Cover Fastener Location 3000 Speed Nut one side One fostener P 65 Button Plug 10 One fastener for the choin on each side lubrication hole 90111 3 02 95 1 20 D Figure 8 Cover Fastener Location 3600 RC One fostener front One fastener 4 Connector 2 on eoch side 0 1 Spec is nn SHa rma Cle e laur 90112 A 3 02 95 1 20 Figure 9 Cover Fasteners Cover Fostener Side
28. COLORS r1 BLK GROUND 2 WHT L5 RED REVS 4 GRN IL SE 88 SERIAL L BLU 5 7 08 2 76 VIEW C Power Connector 1 PUR POS 2 WHT NEG 3 GRNXYEL E 4 BLU SERIAL To Holl Effect Sensor 90020 C 2 18 95 WIRING DIAGRAMS Wiring Diagram 3 Serial Cable Assembly PIN 1 PIN 2 PIN 3 BRN 4 RED P PIN 1 WHT POS PIN 2 BLK NEG PIN 3 BRN GND PIN 4 RED SERIAL 90021 8 3 02 95 1 2 77 WIRING DIAGRAMS Wiring Diagram 4 8 D C Power Cable Assembly zm 1 N 2 274 N Domm T i 112 21 Page 78 Description Console Assembly 3000 CE Console Assembly 3600 RC Lock washer 1 4 Screw 1 4 20 x 3 4 Finishing cap Finishing washer 1 4 Bolt 3 8 16 x 2 3 4 Flat washer 3 8 Nyloc nut 3 8 16 Screw 3 8 16 x 2 3 4 Cover fastener Speed nut Screw 48 x 5 8 Neck cover right 3000 CE Neck cover left 3000 CE Side cover right 3000 CE Side cover left 3000 CE Side cover right 3600 RC ide cover right 3600 R Drive chain 3000 CE Reading rack 3000 CE Footstrap right Footstrap left Pedal right Pedal left Drive chain 3600 RC Master link Wheel 3 diameter Cotter pin Clevis pin Leveling adjustment cap Main cable 3600 RC Screw 312 18x 1 Flat washer 1 4 Nyloc nut 1 4 Manin cable 3000 CE Poly
29. D WIRING DIAGRAMS 73 Poly V pulley 12 diameter ran 76 Intermediate shaft 7 Freewheel sprocket 4 79 81 Chainring cov cec Bearing nut a sembiy right side Bearing nut assembly left side Crank jam nut Hall effect sensor assembly e pee zu Grommet cover 3600 RC 7 Ojo S a S Buttonplug Wall mounted power supply WP 1 EP LO ple bike power supply international Serial cable assemb 7 0 1 de 3000 Page 81
30. HE POWER SUPPLY APPROVED FOR USE WITH THIS EQUIPMENT IN ADDITION YOUR MACHINE MUST BE PROPERLY GROUNDED e Connect the DC power cable to the connector located just inside the right or left side cover of the Spinnaker systems cycle ergometer refer to Figure 7 or 8 Ensure the power connector cap is installed on the power connector not in use Connect the other end of the DC cable to the power supply Place the IPS 3 model power supply on the floor near the AC outlet closest to the bike Plug the AC power cord into the AC wall outlet Connect the other end of the AC power cord to the IPS 3 model power supply Switch on the power supply and observe the console It should emit a tone scroll a software revision level message across the text bar and display the ATTRACT mode on the console screen If the console does not do this switch off the power supply and then turn it back on If the sound and or the displays are still not present call the local StairMaster Sports Medical Products Inc distributor 6 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 To change the language of the prompts press UP ARROW 7 4 2 4 ENTER Press the code number corresponding to the desired language according to Table 1 and then ENTER If the software version does not hav
31. LESHOOTING WP 1 POWER SUPPLY ll Symptom The console powers up but blanks out while someone is serin A Verify both the AC and the DC power The problem may be a loose connection or a bad cable Verify the power as outlined in the previous Troubleshooting section of this Manual Just moving the cables and the connections during the tests may pinpoint the problem B Check for excessive voltage drop If the AC and the DC power tests produce positive results the problem is either an inoperable power supply or an inoperable console 1 Remove the DC power connector cap from the unused connector located just inside the side cover Use a DC voltmeter to check the pins on the DC power connector inside the cover Pin 1 is positive and pin 2 is negative 2 If there are less than 8 VDC at the connector then either the power supply or the console is inoperable Continue testing at step 3 If the reading is between 8 14 VDC call the Customer Service Department of StairMaster Sports Medical Products Inc for additional assistance 3 Replace exchange the power supply and repeat step 1 If the problem still exists go to step 4 4 Replace or exchange the console and repeat step 1 If the problem still exists call the Customer Service Department of StairMaster Sports Medical Products Inc 9 ELECTRICAL TROUBLESHOOTING WP 1 POWER SUPPLY e Symptom The speed RPM feedback is either erratic or wrong A Perform a visual ch
32. The two ends of your bike s lane are enclosed by two lit dots The two bikes on team 1 are shown the top two lanes The two bikes on team 2 are in the bottom two lanes Using the example race set up in the preceding paragraph bike 1 is in the top lane bike 3 is in the next lane down the middle lane is empty bike 42 is in the fourth lane and bike 4 is in the bottom lane The enclosure dots at the right end of your lane will disappear once the race starts A single enclosure dot remains lit at the left end to indicate your lane On the first lap of the race your bike is shown as a single dot traveling from left to right across the display When your bike gets to the far right side of the display the dot will drop down a row and move back toward the starting line from right to left One dot is added to your bike at the start of each lap For example your bike is shown as one dot on the first lap and as five dots on the fifth and final lap Remember you have to complete one lap as a 5 dot bike before a 5 mile race is over The default statistic in the text bar is your pedal rate expressed in RPMs The number of laps remaining are counted down at the right side of the text bar The performance feedback can be changed from the default peda rate by pressing the desired button on the function keypad The number of the bike on your team that is drafting is shown in parentheses between the performance feedback and the lap counter Page
33. Troubleshooting the Electrical System 29 Diagnostic TOO ect rr irt m iz ote 40 Troubleshooting the Drive 42 PARTS REMOVAL AND REPLACEMENT 1921 45 Dee 46 SA LL ES 45 Crank and Bottom Bracket 53 DING al EE 49 1 79 50 Fan Shaft Assembly 192 51 Eed a Ol Handlebar Console Mounting Tue 46 One Aebi u Phi Rind 50 Seege 53 Page vi 9 rei eias arse 7 50 dc 50 ET 47 Seat Location Post 3000 CE trt tiis 48 Seat 3600 RE Of u u ASR 49 GROUNDING INSTRUCTIONS 55 NOTICEOE EGG 56 APPENDICES How to Order Parts E NE LAV ASS Ee 57 Figures 5 21 ERN E 58 Wiring Diagrams T uu sss ikin raki 75 Key to Figures 5 21 and Wiring Diagrams 1 4 79 LIST OF ILLUSTRATIONS Figure 1 Spinnaker Systems Console BASIC EXERCISE Program 11 Figure 2 Spinnaker Systems Console
34. able unit The serial number of the inoperable unit located on the frame The date s of purchase for the inoperable unit s Your billing address This information wil enable StairMaster Sports Medical Products Inc to ensure that you are the only one ordering parts under your warranty protection If warranty replacement parts are shipped to you StairMaster Sports Medical Products Inc may require that the inoperable part be returned To facilitate this process the following policy has been established Please call the Customer Service Department of StairMaster Sports Medical Products Inc to receive a return goods authorization prior to shipment StairMaster Sports Medical Products Inc will incur all freight i e shipping and handling charges for warranty parts ordered for a product that is less than 45 days old The parts will be shipped to you via an overnight courier The customer is responsible for freight charges on warranty parts for product that are more than 45 days old Customers will not be responsible for the EZ return shipment of the inoperable parts see below e Some inoperable warranty parts must be promptly returned to the Customer Service Department of StairMaster Sports Medical Products Inc The freight charges for the return of inoperable warranty parts will be paid by StairMaster Sports Medica Products Inc detailed instructions are included with each warranty replacement part shipment Stai
35. amp for example If the AC wall outlet is supplying the correct power proceed to step 3 If the voltage is outside the specified range or if the device does not work when plugged into the wall outlet consult an electrician for further assistance and then retest the outlet Plug the power supply into the AC wall outlet and then verify the DC power Verify DC power 1 Make sure that the power supply is plugged into an AC wall outlet that is operational Unscrew the DC power cord from the connector located just inside the side cover Use a DC voltmeter to verify the DC power at the DC connector at the end of the cord from the power supply refer to Wiring Diagram 1 Pin 1 is positive and pin 22 is negative the voltage should range between 9 and 15 VDC If the VDC is within range proceed to step 43 Replace the power supply if the DC voltage is not within the specified range and retest the new power supply Remove the console Unscrew the main cable from the back of the console Reconnect the DC power cord to the connector located just inside the side cover Use a DC voltmeter to verify 9 15 VDC at the main cable connector Pin 1 is negative and pin 9 is positive refer to Wiring Diagram 3 If the VDC is outside the range replace the main cable and then retest the new cable at the connector If the power is within the range the console is inoperable and must be replaced Page 31 ELECTRICAL TROUB
36. ay the ATTRACT mode on the console screen If it does not do this unplug the power supply and plug it back in If the sound and or the displays are still not present call the Customer Service Department of StairMaster Sports Medical Products Inc at 800 331 3578 International customers may contact their local distributor Goto step 6 Group race power supply configuration To connect multiple Spinnaker systems cycle ergometers up to a maximum of five to take advantage of the group race features perform the following steps Ensure that the input AC power rating marked on the power supply matches the available power and that you are not using the wall mounted power supply If you do not have the correct power supply contact the Customer Service Department of StairMaster Sports Medical Products Inc at 800 331 3578 to order the correct power supply before proceeding International customers may contact their local distributor INSTALLATION INSTRUCTIONS TO REDUCE RISK OF ELECTRICAL SHOCK AND FIRE DO NOT CONNECT MORE THAN FIVE 5 SPINNAKER SYSTEMS CYCLE ERGOMETERS TO THE PS 5 MODEL POWER SUPPLY USE ONLY THE POWER SUPPLY APPROVED FOR USE WITH THIS EQUIPMENT IN ADDITION YOUR MACHINE MUST BE PROPERLY GROUNDED Line up the Spinnaker systems cycle ergometers in a row Although other configurations may be used for the sake of clarity the following instructions will address a single row Connect the DC p
37. ber the jam nut and the pedal have reverse threads tighten them in the counterclockwise direction Adjust the side play in the crank by tightening or loosening the left side bearing nut with a 32 mm cone wrench The crank should spin freely without binding When the crank is properly adjusted hold the left side bearing nut with the cone wrench and tighten the jam nut securely Recheck the crank adjustment after you ve tightened the jam nut Install the drive chain and the side and neck covers Page 54 GROUNDING INSTRUCTIONS 9 Spinnaker systems cycle ergometer must be grounded If it should malfunction or break down grounding provides the path of least resistance for the electric current thereby reducing the risk of electric shock This machine is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances A WARNING IMPROPER CONNECTION OF THE EQUIPMENT GROUNDING CONDUCTOR CAN RESULT IN THE RISK OF ELECTRIC SHOCK CHECK WITH A QUALIFIED ELECTRICIAN OR SERVICEMAN IF YOU ARE IN DOUBT AS TO WHETHER THE MACHINE 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 A QUALIFIED TECHNICIAN The Spinnaker systems cycle ergometer is designed for use on a nominal 120 volt
38. caps to compensate for uneven floors Each face of the square cap is a different thickness refer to Figure 5 If you need to level the bike turn the appropriate adjusting cap s Then check the stability of the bike and readjust the leveling caps if necessary 2 The Spinnaker cycle ergometers which are intended for single bike operation in the United States Canada and Japan use a wall mounted power supply that plugs directly into a 120 volt three prong AC wall outlet refer to Figure 6 This power supply has a permanently attached DC power cord that connects to a single Spinnaker systems cycle ergometer WARNING TO REDUCE RISK OF ELECTRICAL SHOCK AND FIRE DO NOT CONNECT MORE THAN ONE SPINNAKER SYSTEMS CYCLE ERGOMETER TO THE WP 1 MODEL POWER SUPPLY DO NOT ATTEMPT TO USE A STAIRMASTER PS 5 POWER SUPPLY Spinnaker systems cycle ergometers that are serially linked for the group racing and team race option as well as Spinnaker systems cycle ergometers that are sold for use outside of the United States Canada or Japan both single use and serially linked use different power supplies refer to Figure 6 These power supplies are small floor models with cables that must be connected to the power supply unit WARNING TO ELIMINATE A POSSIBLE FIRE OR SHOCK HAZARD AND TO PREVENT SEVERE DAMAGE TO THE MACHINE USE ONLY THE POWER SUPPLY APPROVED FOR USE WITH THIS EQUIPMENT IN ADDITION YOUR MACHINE MUST BE PROPERLY GROUNDED
39. ced If the problem still exists contact the Customer Service Department of StairMaster Sports Medical Products Inc for further assistance ELECTRICAL TROUBLESHOOTING IPS 3 POWER SUPPLY Single Use Spinnaker Systems Cycle Ergometers Operated Outside Un States Canada and Japan Symptom The console fails to power up A Perform a visual check Check the following things first 1 2 Is the power supply plugged Is the green light lit on the power supply If the light is not on is the power supply switched on and or does the circuit breaker need to be reset Are all the cables properly connected to the power supply and the machine B Verify AC power 1 Disconnect the power cord from the power supply and the AC wall outlet Verify that the AC wall outlet is supplying the correct power in one of two ways a Use an AC voltmeter to verify that the AC line voltage is between 220 and 240 VAC at the AC outlet b Plug in an alternate AC powered device a lamp for example If the AC wall outlet is supplying the correct power to to step 3 If the voltage is outside the specified range or if the device does not work when plugged into the wall outlet consult an electrician for further assistance and then retest the outlet e Plug the AC cord into the AC wall outlet and verify that the AC line voltage is between 220 and 240 VAC at the opposite end of the cord Go to step 4 if the AC
40. ced or exchanged Display Test Use this test if the console display or the text bar exhibits blank spots during use This test checks for inoperable light emitting diodes LEDs in the console display and the text bar If any LED will not light replace the console 1 Press 0 to start the test 2 All LEDs in the console display should be lit The 26 alpha characters A Z and 10 numeric characters 0 9 will scroll across the text bar 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 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 mode code due to an inoperable keypad replace the console 1 Press 2 to start the test 2 The display LEDs will light up in an L shaped formation representing the keypad matrix Pressing button on either the exercise program 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 must be replaced 4 Pressing the CLEAR button will light that LED and then end the keypad
41. close to the floor as possible The knee of the extended leg should be slightly bent when the sole of your foot is parallel to the floor If you need to adjust the seat height get off the bike and stand to one side The seat adjustment knob is located on the frame tube just below the front part of the seat Hold onto the seat with one hand and pull out on the seat adjustment knob with your other hand Lower or raise the seat as necessary A WARNING TO ELIMINATE THE RISK OF INJURY DO NOT ADJUST THE SEAT HEIGHT WHILE ON THE SPINNAKER 3000 CE CYCLE ERGOMETER MAKE SURE THAT THE SEAT ADJUSTMENT PIN COMPLETELY ENGAGES THE HOLE IN THE SEAT POST BEFORE REMOUNTING THE BIKE Seat Height Adjustment on the Spinnaker 3600 RC Cycle Ergometer Sit on the seat Put both feet onto the pedals and into the footstraps Pedal slowly and stop when one leg is extended The knee of the extended leg should be slightly The seat adjustment lever is in front of the seat base Remain seated and keep your feet on the pedals Pull up on the lever and slide forward or backward as necessary Release the lever and make sure the seat is locked in place by trying to move the seat forward and backward Footstrap Adjustment To ensure your feet are properly secured to the pedals you need to check the position of the footstraps Position your foot so that the ball of your foot is over the pedal spindle The pedal footstraps should be tight enough to secure your feet to
42. come a certain amount of wind resistance and the trailing bike has an advantage while riding in the lead bike s slipstream The trailing bike must stay within two dots of the lead bike to remain in the draft If the teammates work together dividing the drafting time they will be able to attain a higher average speed than if one bike is left behind The four people in the race press TEAM RACE to start the race The first person to press TEAM RACE will set up the race Say for example the riders on bikes 41 and 43 are on one team and the riders on bikes 2 and 44 on the other team The person in charge of the race set up will press 1 3 ENTER 2 4 ENTER when prompted to enter the teams Bikes 1 and 3 are on the first team Bikes 2 and 44 on the second team Refer to the Group Race Power Supply Configuration section of the Installation Instructions in this Manual for additional information about setting the bike numbers Select the race distance by pressing a number key and then ENTER A five mile race requires all participants to complete five one mile laps After the race is set up the person in charge must press ENTER All bike s text bars will then show a five second countdown to the start of the race The display for the TEAM RACE is a series of five two lap lanes very similar to the GROUP RACE display refer to Figure 4 with the middle lane empty Each lane is separated by a row of lighted dots
43. d not be pulled out of the base After the fasteners have been removed lift the neck grommet away from the covers Page 45 PARTS REMOVAL AND REPLACEMENT Move the crank to about the eleven o clock position on the right side to get 4 right side cover over the crank Once the right cover is off the frame move the cranks to the one o clock position on the left side and remove the left cover 5 When reinstalling the side covers feed the connector caps and chains through the holes in the side covers To reinstall the fastener reinsert the base of the fastener through the cover and into the frame When the base is in place push the pin in all the way to secure the fastener CONSOLE 1 Disconnect the DC power cable from the connector located just inside the side COVer 2 Remove the neck covers 3000 only 3 Remove the four mounting bolts and associated hardware from the back of the console 4 Unscrew the main cable connector from the back of the console 5 Reverse the steps to reinstall the console HANDLEBAR CONSOLE MOUNTING TUBE 3000 CE 1 Remove the console C 2 Loosen and remove the two nyloc nuts and flat washers from the mounting bolts refer to Figure 10 3 Remove the mounting bolts from the frame tube 4 Hold onto the handlebar with both hands and remove the handlebar console mounting tube from the frame tube You may have to twist the handlebar console mounting tube as you pull up on
44. detect rough spots as you rotate the spindle replace the pedal Repeat this procedure with the other pedal Check the bearing clamps If the allen bolts are loose tighten them and spin the crank If the noise is still present readjust the bearing nut assemblies and spin the crank Remove the crank assembly from the frame if the noise is still present Check the right and left bearing nut assemblies for smoothness of operation Replace the bearing nut assembly if necessary Symptom A clunking or clicking noise is heard while the fans spin and the crank is stationary This noise indicates a problem in the drive reduction train if Remove the neck covers 3000 only and the side covers Examine the area around the flywheel and the Poly V pulley for anything out of the ordinary Slowly turn the crank and see if there are any obstructions in the drive reduction area If the Poly V belt is properly tensioned you will need to check the shaft bearings Watch the fan and intermediate shafts The noise may be in sync with the revolutions of one of the shafts The fan shaft spins at a faster rate than the inermediate shaft you may be able to isolate the problem by observing how often the noise occurs Check the bearings in the noisy shaft and replace if necessary If the noise cannot be isolated in this manner start by removing and checking the intermediate shaft bearings and then the fan shaft bearings Remove both fans and check the pil
45. e specified range and test the new DC cable Remove the console Unscrew the main cable from the back of the console Reconnect the DC cord from the power supply to the DC connector just inside of the side cover Use a DC voltmeter to verify 10 16 VDC at the main cable connector Pin 41 is negative and pin 9 is positive refer 10 Wiring Diagram 3 If the VDC reading is outside the specified range replace the main cable and then retest the cable at the connector If the power is within the specified range the console is inoperable and must be replaced If the problem still exists contact the Customer Service Department of StairMaster Sports Medical Products Inc for further assistance Symptom The console powers up but blanks out during exercise Perform the tests as outlined for Symptom in the Electrical Troubleshooting WP 1 Power Supply section The procedures are the same regardless of the power supply Il Symptom The speed or RPM feedback is either erratic or wrong Perform the tests as outlined for Symptom III in the Electrical Troubleshooting WP 1 Power Supply section The procedures are the same regardless of the AC power supply Page 39 CONSOLE DIAGNOSTIC TESTS The following tests must be performed while the console is in the DIAGNOSTIC mode activate the DIAGNOSTIC mode press the UP ARROW 1 0 7 ENTER If the console fails any test the console should be repla
46. e the faster you pedal the higher the resistance The Spinnaker 3000 is an upright cycle ergometer The relationship between the position of the seat the pedals and the handlebars was designed to maximize the use of the major muscle groups of the lower body the quadriceps the hamstrings the gluteals and the calf muscles The Spinnaker 3600 RC is a semi recumbent cycle ergometer designed to minimize the stress on the knee while maintaining a comfortable seat position WHAT IS IN THIS MANUAL The information presented in this Owner s Manual has been divided into five sections 1 safety guidelines 2 set up and installation instructions 3 operational instructions 4 maintenance instructions and 5 troubleshooting guidelines In order to achieve the greatest results possible from your StairMaster Spinnaker systems cycle ergometer you should read this Manual thoroughly and adhere closely to all instructions and guidelines e Throughout this Manual whenever you are required to enter information into the nsole the console keypad keystrokes are enclosed in The names of the buttons and special console operational modes are shown in capital letters For example the StairMaster Spinnaker systems cycle ergometer is ready for use when the console is in the ATTRACT mode You are then required to press the SELF PACE button to start the SELF PACE exercise program 5 gt e
47. e cadence for the duration of the exercise bout is displayed 2 CYCLING SPEED is the equivalent speed in miles per hour or kilometers per hour if your console is set to metric units you would be traveling on a bicycle outdoors while riding at the same relative intensity During an exercise program this Page 12 SPINNAKER SYSTEMS CONSOLE button displays the current speed After you have completed your exercise program the average speed for the duration of the exercise bout is displayed DISTANCE CYCLED provides a cumulative total of the equivalent distance in miles or kilometers if your console is set to metric units you would have traveled while riding a bicycle outdoors at the same relative intensity TOTAL CALORIES provides a cumulative total of the Calories expended during a particular workout Calories expended is probably the most common way to measure the energy cost of exercise Since the energy content of food is ex pressed in Calories a convenient way exists to control or manage your body weight When your total energy intake is less than your total energy output you lose weight and vice versa Technically a Calorie is a measure of heat One Calorie is the amount of heat needed to raise the temperature of one liter or one kilogram of water one degree Celsius EXERCISE LEVEL provides different information depending on the exercise program you select INTERVAL programs the intensity level during the wo
48. e the desired language contact the Customer Service Department at StairMaster Sports Medical Products Inc to obtain the Page 6 INSTALLATION INSTRUCTIONS correct software version To change the console to metric units press UP ARROW 9 7 6 0 ENTER Press 1 ENTER when prompted To change the console to back to English units press UP ARROW 9 7 6 0 ENTER Press 0 ENTER when prompted Table 1 Language Codes Language Code Number Version A Version Version C xl 2x n Macc E e 12 Your StairMaster Spinnaker systems cycle ergometer is now ready for use PHYSICAL DIMENSIONS AND ELECTRICAL SPECIFICATIONS OF THE STAIRMASTER SPINNAKER SYSTEMS CYCLE ERGOMETER The dimensions and electrical specifications of the StairMaster Spinnaker systems cycle ergometer are listed in Table 2 To reduce the hazard of electrical shock place the power supply in a location away from the machine and away from exposure to perspiration Do not place the power supply on a carpet because the power supply may overheat mount power supplies should be plugged directly into the AC wall outlet Custom length DC cables brackets for multiple power supplies and other accessories are available from StairMaster Sports Medical Products Inc Refer to the Appendix How to Order Parts for the phone number of the office nearest you Page 7
49. eck 1 Remove the neck covers 3000 CE only and the side covers Do not disconnect the DC power cable from the connector on the frame 2 Make sure the main cable and hall effect sensor wires are connected refer to Wiring Diagrams 2 and 3 3 Check the clearance between the hall effect sensor and the magnet mount The maximum clearance is 1 4 0 6 cm ensure the magnet mount does not contact anything as the fan shaft rotates 4 Hold the fans and try to turn the magnet mount with your free hand If the magnet mount turns on the fan shaft tighten the magnet mount bolts B Verify the AC and the DC power The problem may be a loose connection or a bad cable Verify the power as outlined in the first Troubleshooting section of this Manual Just moving the cables and the connections during the tests may pinpoint the problem C Check the hall effect sensor circuits 1 Disconnect the plastic connector at the junction of the wires from the hall effect sensor and the main cable wires refer to Wiring Diagram 3 e Use a DC voltmeter to check the VDC at the main cable connector Pin 1 the red wire is negative and pin 44 the orange wire is positive The reading should range between 4 8 5 2 VDC If it does not proceed to step 32 If the VDC is within the range go to step 3 2 If the VDC reading is outside the specified range check for continuity in the main cable refer to Wiring Diagram 3 Unplug the power supply
50. er in one of ways a Use an voltmeter to verify that the AC line voltage is between 100 and 120 VAC or between 220 and 240 VAC if applicable at the AC wall outlet or b Plug in an alternate AC powered device a lamp for example If the AC wall outlet is supplying the correct pwer go to step 3 If the voltage is outside the specified range or if the device does not work when plugged into the wall outlet consult an electrician for further assistance and then retest the outlet Plug the AC cord into the AC wall outlet and verify that the AC line voltage is between 100 and 120 VAC or between 220 and 240 VAC if applicable at the opposite end of the cord Go to step 4 if the AC line voltage is within range Replace the cord if the voltage is not within the specified range and then test the new cord Reconnect the AC power cord to the power supply and proceed to section D D Verify DC power k Make sure that the AC power cord is properly connected to the power supply and that the AC wall outlet is delivering the proper voltage Turn on the power supply The indicator light on the front pane should be lit If it is proceed to step 3 If the indicator is not lit when the switch is on reset the circuit breaker If the light is still not lit replace the power supply and test the new power supply 0 Disconnect the DC cable from the power supply Use DC voltmeter t verify the DC power at the DC connect
51. from the AC wall outlet Unscrew the main cable from the back of the console Place one lead of the multimeter at the console connector end of the cable and place the other lead at the main cable connector to the hall effect sensor wires the connector you disconnected in step 1 e Set the multimeter to the continuity check mode on most meters this will be the resistance or ohms setting Check for continuity through the main cable at pins 1 the red wire 43 the green wire and 4 the orange wire e If there is continuity through the cable the reading is near Page 33 ELECTRICAL TROUBLESHOOTING WP 1 POWER SUPPLY amp zero ohms the cable is good and the console must be replaced If there is no continuity through the main cable at any of the pins replace the cable 3 If the VDC reading is within the specified range check for continuity in the main cable at pin 3 refer to Wiring Diagram 3 Unplug the power supply from the AC wall outlet Unscrew the main cable from the back of the console Place one lead of the multimeter at the console connector end of the cable at pin 3 the green wire and place the other lead at the green wire on the main cable connector to the hall effect sensors wires the connector you disconnected in step 1 e Setthe multimeter to the continuity check mode on most meters this will be the resistance or ohms setting if continuity exists through the cable the reading is
52. fter you pedal 40 revolutions per minute for at least five seconds Press ENTER when prompted The BASIC EXERCISE program is a self paced workout that calculates all metabolic feedback except MET Level Two dots will light up at the bottom of the display refer to Figure 1 As you pedal the dots will advance around the perimeter of the display in a clockwise direction Each lap around the display is equivalent to 1 4 of a mile The faster you pedal the faster the dots move The elapsed time of your workout in minutes seconds is shown in the middle of the display The left side of the text bar displays your current pedal rate in revolutions per minute Press 2 CYCLING SPEED to change the text bar feedback from pedal rate to cycling speed in miles per hour or in kilometers per hour if your console is set up for metric units Press WORKOUT STATS and all of the performance feedback will continuously scroll across the text bar with the exception of MET Level Press CLEAR to end the BASIC EXERCISE program Your summary workout sta will scroll across the text bar You can press any function keypad button during the scrolling summary and stop at that statistic You 10 seconds to press another function keypad button before the console goes into the ATTRACT mode Your workout stats are stored in the console memory until the next exercise program is started Press WORKOUT STATS to scroll the summary information across the text bar
53. hat may have accumulated during shipping Your new machine will require minor assembly Refer to the Installation Instructions section of this Manual for details PREVENTIVE MAINTENANCE The procedures for performing recommended preventive maintenance on the Spinnaker systems cycle ergometer are summarized in Table 6 Cleaning 1 DO NOT USE GLASS CLEANER OR OTHER HOUSEHOLD CLEANERS ON THE CONSOLE Clean the console daily with a water dampened cloth and wipe dry after cleaning 2 Clean the exterior covers the pedals and the seat on a weekly basis using either soap and water or a diluted non mineral based household cleaner such as Fantastic A WARNING TO AVOID INJURY DUE TO SLIPPERY POINTS OF CONTACT DO NOT USE PETROLEUM BASED CLEANERS OR ARMOR ALL TYPE PROTECTANTS ANYWHERE ON THIS MACHINE OR ON THE FLOOR MATS Weekly Inspection 1 Inspect the painted surfaces of the exposed frame for any rust bubbling or chips during the weekly cleaning The salt in perspiration will damage unpainted surfaces Repair the damaged area with a touch up paint kit provided by StairMaster Sports Medical Products Inc Refer to the Parts Key for the touch up kit part number 2 Inspect the pedal footstraps at both the inside and outside attachment sites Replace the footstraps if they are torn or ripped 3 3000 CE only inspect the seat post and the seat adjustment pin The seat post should slide up and down freely in the plas
54. ike gets to the far right side of the display the dot will drop down a row and move back toward the starting line from right to left One dot is added to your bike at the start of each lap For example your bike is shown as one dot on the first lap and as five dots on the fifth and final lap Remember you have to complete one lap as a five dot bike before a five mile race is over The default statistic in the text bar is your pedal rate expressed in RPMs The number of laps remaining are counted down at the right side of the text bar The performance feedback can be changed from the default pedal rate by pressing the desired button on the function keypad If the drafting mode is activated the number of the bike s drafting is shown in parentheses on the text bar between the performance feedback and the lap counter The race does not end until the last bike finishes or quits the race Pressing CLEAR allows you to drop out of the race Pressing CLEAR will also end the race if only one other person remains in the race who has not finished Both your standing in the race and your total time are shown in the text bar after you have completed the race You also have access to all other workout stats except MET Level The race results are stored in the console until the next exercise program is started You can press WORKOUT STATS to review the results of your performance SPINNAKER SYSTEMS CONSOLE CUSTOMIZING THE TEXT BAR SCROLLING
55. in each of the Figures identify the parts which are referenced in the Parts Key of the Appendix TOOL LIST The following tools are needed to perform service and maintenance on the Spinnaker systems cycle ergometer shop goggles or other eye protection e standard screwdriver e snap ring pliers internal snap rings locking pliers snap ring pliers external snap rings phillips screwdriver e combination wrenches sizes 7 16 to 3 4 adjustable width pliers adjustable wrench 15 mm pedal wrench allen wrenches T handled and L bend volt ohm meter ket set or nut driver set sizes 1 4 to 3 4 wire stripper crimper cone wrench freewheel removal tool MAINTENANCE RECORDS The console on the Spinnaker systems cycle ergometer will keep track of the following usage data on the machine the number of hours the machine has been turned on the number of hours the machine has been in use While the console is in the ATTRACT mode the machine usage data can be displayed by pressing UP ARROW 7 7 0 3 and ENTER The console displays the information in the sequence listed above NOTE The console may display several hours of use when your machine first arrives due to the fact that it has undergone testing at the manufacturing facility MAINTENANCE INSTRUCTIONS INITIAL SERVICE Upon receiving new Spinnaker systems cycle ergometer use a soft clean towel 10 wipe off the dust t
56. ling and one period of fast Page 16 SPINNAKER SYSTEMS CONSOLE pedaling In this program you are required to pedal slowly for 45 seconds and then pedal fast for 15 seconds before the cycle is repeated INTERVAL TWO alternates two slow interval periods a total of 30 seconds with two fast interval periods a total of 30 seconds INTERVAL THREE alternates 15 seconds of slow pedaling with 45 seconds of fast pedaling Press the desired INTERVAL program button You are also required to enter your body weight the intensity level from 1 the easiest to 20 the most difficult and the duration from 5 to 45 minutes The display is equivalent to a 1 10 mile race track Your bike is repre sented as two dots in the outer lane The computer pacer is the single dot in the inner lane The computer pacer will advance in a clockwise direction around the perimeter of the display as soon as the program starts Your objective is to pedal to keep up with the pacer The faster you pedal the faster your dots move and vice versa The target pedaling rate is shown in the middle of the display As a default the text bar displays pedal rate Your pedal rate is shown above the ACTUAL deadfront The units are displayed to the right of the numbers in this case the feedback units are pedal revolutions per minute RPM The computer pacer pedal rate is shown above the TARGET deadfront The number of intervals left in the program are shown above the TIME
57. low block bearing set screws They should be snug Check the nut on the left end of the intermediate shaft it should also be tight Reinstall the fans spin them and listen for noise If the noise is still present go to step 4 Remove the intermediate shaft assembly and the fan shaft assembly Inspect the fan shaft bearings for smoothness of operation Replace the bearings if necessary Page 43 TROUBLESHOOTING THE DRIVE TRAIN 5 Remove the intermediate shaft from the Poly V pulley Inspect the intermediate shaft bearings for smoothness of operation Replace the bearings if necessary Check the freewheel for smoothness of operation in the counterclockwise direction and positive engagement in the clockwise direction If the freewheel sticks or fails to engage replace it Reassemble the drive train Turn the crank if the noise is still present call the Customer Service Department of StairMaster Sports Medical Products Inc for further assistance PARTS REMOVAL AND REPLACEMENT 3000 CE The Spinnaker 3000 CE cycle ergometer is protected by four plastic covers two large side covers and two smaller neck covers Refer to Figure 6 for the fastener locations 1 The neck covers are held in place with six screws one on each side two on the front and two on the rear The neck covers must be removed before the side covers are removed Disconnect the DC power cable from the connector located just inside the botto
58. m front corner of the side cover The side covers are held in place with four reusable fasteners Slide either end of the fastener removal tool under the edge of the pin head and pull the pin out about halfway refer to Figure 9 The pin should not be pulled out of the base After the fasteners have been removed lift the square rubber grommet away from the base of the seat post Move the crank to about the eleven o clock position on the right side to get the right side cover over the crank Once the right cover is off the frame move the cranks to the one o clock position on the left side and remove the left cover When reinstalling the side covers feed the connector caps and chains through the holes in the side covers To reinstall the fastener insert the base of the fastener through the cover and into the frame When the base is in place push the pin in all the way to secure the fastener Connect the DC power cable to the power connector once the side covers are in place 3600 RC Spinnaker 3600 cycle ergometer is protected by two plastic side covers Refer to Figure 7 for the fastener locations 1 Disconnect the DC power cable from the connector located just inside the bottom rear corner of the side cover The side covers are held in place with five reusable fasteners Slide either end of the fastener removal tool under the edge of the pin head and pull the pin out about halfway refer to Figure 9 The pin shoul
59. n minutes seconds is shown in the middle of the display The FIT TEST is a program that estimates your maximal aerobic capacity based on your heart rate response to submaximal exercise You will be prompted to enter your body weight your age and your gender Once you have entered the required information two dots will light up at the bottom of the display As you pedal the dots will move around the display in a clockwise direction The target pedaling rate is shown in the middle of the display Your actual pedaling rate as well as the target pedaling rate is shown in the text bar The goal is to match your pedaling rate to the target pedaling rate The timer will count down in seconds The FIT TEST is a modified YMCA protocol You will warm up for three minutes 180 seconds at a steady pace and then be prompted to enter your heart rate You have five seconds to find your pulse and 10 seconds to count your pulse Enter the 10 second count when you are prompted If you are using a heart or pulse rate monitor enter your heart rate at the end of the ten second period You will then continue to exercise for three minute bouts of increasing intensity until you reach a point where you have entered two heart rate responses between 19 and 25 counts 115 150 beats per minute This test typically lasts from 9 to 15 minutes At the end of the FIT TEST your results will be scrolled across the text bar Your estimated maximal aerobic capacity expres
60. ndard screwdriver to turn the bolt Ideally the seat should slide easily without excessive side play Tighten the nuts after the wheels are adjusted Page 47 1 2 10 11 12 PARTS REMOVAL AND REPLACEMENT SEAT LOCATION POST 3000 CE ONLY Pull the seat adjustment knob out and raise the seat Insert a phillips screwdriver into one of the holes in the seat post which are located above the seat tube cap refer to Figure 11 Gently lower the seat so that the seat is held up by the screwdriver The seat adjustment shaft will be protrud ing slightly because the shaft is between the holes in the seat post Hold the seat adjustment shaft with a pair of locking pliers and remove the seat location knob from the shaft by turning the knob counterclockwise Remove the screwdriver from the hole in the seat post and lower the seat slightly so the seat adjustment shaft engages a hole in the seat post This will reduce the tension in the spring return mechanism A WARNING TO REDUCE THE RISK OF EYE INJURY WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS Remove the outermost snap ring Unweight the seat post by applying a slight upward force to the bottom of the seat Pull out the seat adjustment shaft removing both washers and the spring at the same time Insert a phillips screwdriver into one of the holes in the seat post which are located above the seat tube cap Remove the snap ring located in front of the seat select
61. nner lane The computer pacer advances in a clockwise direction around the perimeter of the display as soon as the program starts In this race you are required to pedal to keep up with the pacer The faster you pedal the faster your dots move and vice versa The total number of laps is counted down to one in the middle of the display As your dots travel around the display perimeter a finish line arrow light up with lap to go The goal is to tie or beat the pacer to the finish line you picked the variable pace race start sprinting on the last lap The AHEAD deadfront will briefly flash if you beat or tied the pacer to the line The BEHIND deadfront will flash if the pacer beat you to the line After the race is completed the program lets you cool down for one minute The pacer dot disappears to signify the start of the cool down period Your workout stats are scrolled across the text bar after the cool down period Your results are stored in the console until the next exercise program is started You can press WORKOUT STATS to review your results 7 The GROUP RACE is a race involving from two to five bikes To start the GROUP RACE every participant needs to press GROUP RACE The first person to press GROUP RACE is required to respond to the race setup prompts The participants can choose to race with or without the drafting function activated The person in charge of the race setup must press YES to activate the draft mode or
62. oly V belt is slack Page 51 6 10 11 12 13 14 15 PARTS REMOVAL AND REPLACEMENT Loosen the mounting nut and remove the magnet mount from the left side A fan shaft Loosen the four pillow block bearing set screws on the right and left side fan shaft brackets refer to Figure 17 Loosen and remove the hall effect sensor mounting nuts and screws Cut the tywrap that holds the sensor cable to the left side fan shaft bracket Set the hall effect sensor to the side Support the flywheel and remove the two bolts from the threaded spacer Carefully lower the flywheel onto the Poly V pulley Support the intermediate shaft bracket and remove the nut and bolt from the top of the intermediate shaft bracket Lean the intermediate shaft bracket out of the way Hold onto the flywheel and slide the left side fan shaft bracket off the fan shaft Slide the Poly V belt off the flywheel Remove the right side fan shaft bracket and flywheel as a unit from the frame Remove the right side fan shaft bracket from the fan shaft once the assembly is away from the frame Inspect the pillow block bearings for smoothness of operation The pillow block bearing assemblies can be removed from the fan shaft brakcets by loosening removing the two jamnuts lock washers and screws Reverse the steps to reinstall the fan shaft assembly Additionally ensure that The short side of the j bolt hook faces to the rear of the f
63. or bushing Remove the two screws securing the seat tube cap to the frame Remove the screwdriver from the seat post Raise the seat tube cap up and away from the frame Push the seat location post forward so the seat adjustment bushing is moved slightly forward in the bushing housing Insert a standard screwdriver between the seat post and the seat adjustment bushing and gently pry the bushing farther out of the bushing housing and out of the way of the nylon seat post guides Page 48 PARTS REMOVAL AND REPLACEMENT e Remove the grommets from the holes in the seat tube Pull the seat post up and out of the frame 14 Reverse the steps to reinstall the seat post in the frame SEAT TRAY 3600 RC ONLY 1 Remove the right side cover 2 Remove the seat 8 Loosen and remove the three nyloc nuts bolts and flat washers that fasten the seat tray to the frame refer to Figure 13 4 Reverse the steps to reinstall the seat tray DRIVE CHAIN 1 Remove both neck covers 3000 CE only and the right side cover 2 Slowly rotate the right pedal As the chain rotates locate the master link 3 Remove the master link retaining plate with a standard screwdriver Use the flat of the screwdriver to push the retaining plate off the pins 4 Remove the master link from both ends of the chain Remove the chain from the chainring and freewheel Reverse the steps to install the chain Ensure that the closed end of the master
64. or on the power supply front panel refer to Wiring Diagram 5 Pin 1 is positive and pin 2 is negative The voltage should range between 10 and 16 VDC If it does go to step 4 Replace the power supply if the DC voltage is not within the specified range and test the new power supply Reconnect the DC cable to the power supply front panel Disconnect the cable from the DC power connector located just inside the side cover Use a DC voltmeter to verify 10 16 VDC at this end of the cable Pin 1 is positive and pin 22 is negative refer to Wiring Diagram 5 If the VDC is within range go to step 5 Replace the DC cable if the VDC is outside the specified range and test the new DC cable Remove the console Unscrew the main cable from the back of the console 6 Reconnect the DC cord from the power supply to the DC connector just inside of the side cover Use a DC voltmeter to verify 10 15 VDC at the main cable connector Pin 2 is negative and pin 9 is positive refer to Wiring Diagram 3 If you have no power at pins 2 and 9 check pins 1 negative and 8 positive The correct pin combination depends on which side the power supply is connected Getting the correct reading not the pin combination is the issue If the VDC reading is outside the specified range replace the main cable and then retest the cable at the connector If the power is within the specified range the console is probably inoperable and must be repla
65. or the GROUP RACE setup UP ARROW 2121 Turns on the custom scrolling message NITER OES Turns off the custom scrolling message UP ARROW 7424 Changes the language of the console prompts refer to the NTER Installation Instructions for the language code number UP ARROW 7607 Allows you to program a scrolling message for the AT TRACT ENTER mode 99 ENTER ext 08 0111109 message editing function UP ARROW 7703 Displays machine usage information R 2 9 9760 Allows you to change the units displayed by the console 0 Changesthe console to English units hanges the console to metric units Page 24 MAINTENANCE INSTRUCTIONS If you keep your StairMaster Spinnaker systems cycle ergometer properly serviced and in good condition it will operate more efficiently and last longer It is strongly recom mended that you adhere to the maintenance service guidelines presented in this Owner s Manual Read all maintenance instructions thoroughly before beginning work In some instances the use of an assistant is recommended to perform the necessary task efficiently All references to the right the left side and to the front or the back of the Spinnaker systems cycle ergometer are made as if you were sitting on the machine ready to exercise For example the drive chain is on the right side of the bike Major component names and locations are shown in Figures 9 and 10 The circled numbers
66. ove the nuts at the top and bottom of the intermidiate shaft bracket refer to Figure 19 Loosen the j bolt nut so the Poly V belt is slack Loosen the mounting nut and remove the magnet mount from the left side of the fan shaft Loosen the pillow block bearing set screws on the left side fan shaft bracket refer to Figure 17 Loosen and remove the hall effect sensor mounting nuts and screws Cut the tywrap that holds the sensor cable to the left side fan shaft bracket Set the hall effect sensor to the side Support the flywheel and remove the two bolts from the threaded spacer Carefully lower the flywheel onto the Poly V pulley Support the intermediate shaft bracket and remove the nut and bolt from the top of the intermediate shaft bracket Lean the intermediate shaft bracket out of the way Page 50 PARTS REMOVAL AND REPLACEMENT e Hold onto the flywheel and slide the left side fan shaft bracket off the fan shaft 12 Slide the Poly V belt off the flywheel Remove the right side fan shaft bracket and flywheel as a unit from the frame Loosen and remove the nut from the left side of the intermediate shaft Pull the intermediate shaft out of the intermediate shaft bracket Remove the Poly V pulley and Poly V belt from the intermediate shaft bracket Inspect the intermediate shaft bearings they are inside the Poly V pulley for smoothness of operation Replace the bearings if necessary Inspect the free
67. ower cable to either the machine on the far left or the far right hand end of the row Use the connector located just inside the right side cover if you are connecting the far right bike or the left side cover if you are connecting the far left bike Connect the other end of the DC cable to the power supply Place the PS 6 model power supply on the floor near the AC wall outlet closest to this bike Plug the AC power cord into the AC wall outlet Connect the other end of the AC power cord to the PS 6 model power supply Switch on the power supply and observe the console It should emit a tone scroll a software revision level message across the text bar and display the ATTRACT mode on the console screen If it does not switch off the power supply and then turn it back on If the sound and or the displays are still not present call the Customer Service Department at e StairMaster Sports Medical Products Inc If the console is working properly turn off the power supply and connect one end of the serial cable to the free power connector on this bike Connect the other end of the serial cable to the power connector on the next bike in line Continue linking the remaining bikes with serial cables Turn on the power supply f any console fails to power up call the Customer Service Department at StairMaster Sports Medical Products Inc Finally set the console address numbers so that race information can be sent to all
68. part or to get help with the troubleshooting process contact the Customer Service Department of StairMaster Sports Medical Products Inc at 800 331 3578 International customers should contact their local distributor or call 206 823 1825 TROUBLESHOOTING THE ELECTRICAL SYSTEM Spinnaker systems cycle ergometers that are set up for single bike operation in the United States Canada and Japan use a wall mounted power supply that plugs directly into the wall AC power outlet This power supply has a permanently attached DC power cord that connects to one Spinnaker systems cycle ergometer Do not connect more than one Spinnaker systems cycle ergometer to the same wall mounted power supply Spinnaker systems cycle ergometers that are serially linked for the group racing option or that are sold for use outside of the United States Canada and Japan both single use and serially linked must not use the wall mount power supplies The proper power supplies are floor models with cables that must be connected to the power supply unit as well as to the wall AC power outlet and to the DC power connector on the side cover refer to Figure 8 Power supplies are not interchangeable You must use the correct power supply your application The troubleshooting procedures are organized according to the type of power supply Make sure you are following the correct troubleshooting procedures The electrical system of your Spinnaker systems c
69. rMaster Sports Medical Products Inc neither makes assumes nor authorizes any representative or other person to make or assume for us any other warranties 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 StairMaster Spinnaker systems cycle ergometer only authorized replacement parts can be used This warranty is void if any parts other than those provided by StairMaster Sports Medical Products Inc are used Note Aerosol products cannot be transported via air Page iv INTRODUCTION o StairMaster Spinnaker systems cycle ergometer is a highly effective tool for developing and improving lower extremity strength and aerobic capacity It is also an integral part of a successful well balanced weight management program The StairMaster Spinnaker systems cycle ergometer is designed for use by individuals of all ages and fitness levels Your purchase of this machine is a positive affirmation of your commitment to use the best means available to develop a high degree of functional fitness The StairMaster Spinnaker systems cycle ergometers use the air pressure generated by crank driven fans for resistance Just like a road bicycl
70. rame The wider portion of the threaded spacer faces to the right You use a new tywrap on the sensor cable and the left side fan shaft bracket Ensure the wires are fully seated in the white plastic connector The magnet mount is as close to the hall effect sensor as it can get while not contacting the hall effect sensor as the fan shaft turns The magnet mount can be up to 1 4 inch 0 6 cm away from the hall effect sensor e The fans are installed according to instructions in the Fan section of the Manual The drive chain is adjusted according to the procedure outlined in the Drive Chain section of this Manual The Poly V belt is adjusted so the distance between the edges of the top and bottom spring retainers on the j bolt is between 1 7 16 and 1 9 16 inches 3 7 4 0 cm refer to Figure 18 Page 52 PARTS REMOVAL AND REPLACEMENT Use a 15 mm pedal wrench or a 5 8 open end wrench to loosen and remove the pedals from the crank The pedal on the left side of the crank has reverse threads Turn the wrench on the left pedal clockwise to loosen it Turn the wrench on the right pedal counter clockwise to loosen it Apply a small amount of multi purpose grease to the threads of the pedal spindle before reinstalling the pedals on the crank The left pedal spindle is marked with an L and the right pedal spindle with R CRANK AND BOTTOM BRACKET ASSEMBLY 1 11 Remove both neck covers 3000
71. rkout the recom mended training level during the workout summary GROUP RACE your placing during the race your placing and elapsed time during the workout summary ROAD RACE the pacer speed during the race the average pacer speed during the workout summary WORKOUT TIME displays the total time in minutes and seconds that you have been exercising POWER OUTPUT provides a measure of how hard you are exercising In order to better understand this measure it is important to appreciate the differences between work power and energy Work is the product of an applied force multiplied by the distance over which the force is applied Power is the rate of doing work or work divided by time Energy on the other hand is the capacity to do work Power output is measured in units known as watts 746 watts 1 horsepower Since power is a rate power output does not accumulate over time and will not change during your workout unless you change your pedal rate During your exercise program this button displays your current power output After you have completed your exercise program the average power output during your workout is displayed MET LEVEL is the relative energy cost of exercise One MET is equivalent to the resting oxygen consumption of about 3 5 milliliters of oxygen per kilogram of body mass per minute ml O kg min For example exercising at 10 METs requires ten times the resting metabolic rate or about 35
72. sed in METs will be the first statistic shown Next your test 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 strand and are shown in Table 3 Your results are stored in the console until the next exercise program is started To review your test results press WORKOUT STATS The POWER TEST is a modified Wingate anaerobic power test This test requires you to enter your body weight age and gender You start the test with a three minute warm up and then are required to perform an all out sprint for 30 seconds The graphic display and text bar feedback for the warm up is the same as described in the FIT TEST above Messages describing the test scroll across the text bar during the warm up With 5 seconds left in the warm up the console will count down to the start of the test Page 15 SPINNAKER SYSTEMS CONSOLE Table 3 Fitness Rating Norms for Spinnaker Systems Cycle Ergometer Aerobic Fitness Test METs O aee E 2029 108 111 123 126160 163197 2006 30 39 97 100 111 114146 148183 186 40 49 86 88100 103134 137 71 174 sosa 21 7488 91123 126157 80 60 69 40 6374 77111 114140 143 ee NOD L 2029 80 8397 100437 140168 171 soso 5183 66103 ZN isi
73. t The UP and DOWN ARROWS also change the computer pacer speed during the ROAD RACE The ENTER button confirms selections and stores the information used to calculate the performance feedback into the console memory The CLEAR button erases data from the console before ENTER is pressed Pressing the CLEAR button once during workout ends the exercise program and begins the workout summary Press the CLEAR button twice to return to the ATTRACT mode The YES and NO buttons are used to respond to data entry prompts The RESET button always returns the console to the ATTRACT mode EXERCISE PROGRAM KEYPAD The exercise program 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 select the desired workout 1 SELF PACE is similar to the BASIC EXERCISE program described earlier with the exception that your MET level can be calculated during the SELF PACE program Page 14 SPINNAKER SYSTEMS CONSOLE You need to enter your body weight and the program duration from 5 45 minutes before starting the program Once you have entered the required information two dots will light up at the bottom of the display As you pedal the dots will move around the display in a clockwise direction Each lap around the display is equivalent to 1 4 of a mile The faster you pedal the faster the dots move The elapsed time of your workout i
74. t 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 UP ARROW 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 when you press ENTER 7 Press the ARROW 2 1 2 3 ENTER to display the default scrolling message on the text bar Page 22 SPINNAKER SYSTEMS CONSOLE e Press ARROW 2 11 2 1 ENTER to display your custom scrolling message on the text bar Table4 Character Codes for the Scrolling Message 0 1 2 3 4 5 6 7 8 9 SPA A B C D E F G H 4 m 23 SPINNAKER SYSTEMS CONSOLE CODES FOR THE SPINNAKER SYSTEMS CONSOLE e There are several console functions that can be accessed by entering a numerical code A list of the codes and the corresponding functions is presented in Table 5 Table 5 Console Codes Code Function UP ARROW 105 Clears the custom programmed scrolling message UP ARROW 107 Activates the Diagnostic mode ENTER 85 2 Keypad test ei c gu ss tt 7 ii 4 Software revision level test ENTER UP ARROW 1746 Set the address numbers f
75. test 10 seconds later CONSOLE DIAGNOSTIC TESTS This test makes sure the hall effect sensor is sending a pulse to the console If you want to verify the console rpm reading count the crank revolutions while pedaling during the tach test and compare your count to the RPM displayed in the text bar 1 Press 3 to start the test 2 The text bar will display the pedal rpm continuously if the hall effect sensor is working properly Refer to the appropriate troubleshooting section if the RPM feedback is either wrong or erratic 3 Press CLEAR to end the test Software Revision Level Test This test allows you to check the version number of the software installed in the console 1 Press 4 to start the test 2 The software version number will scroll across the text bar The console will automatically return to the ATTRACT mode 3 Contact the Customer Service Department of StairMaster Sports Medical Products Inc for the most current software revision updates Page 41 TROUBLESHOOTING THE DRIVE TRAIN Drive train problems are manifested first as unusual annoying noises and then by o damaged and seized parts It is important to accurately diagnose the problem and quickly remedy it Fortunately because the drive train is fairly simple problems with it are relatively easy to identify and repair This troubleshooting section is organized according to the symptoms of the problems which most commonly occur
76. the chain Install the chain and adjust the tension in accordance with the procedures listed in the Parts Removal and Replacement section Lubricate the chain with a spray on chain lubricant such as Tri Flow before installing the cover Annual Maintenance Replace the drive chain annually A WARNING TO AVOID PREMATURE BEARING FAILURE DO NOT LUBRICATE THE SEALED BEARINGS ON THE FAN SHAFT THE INTERMEDIATE SHAFT OR THE CRANK THEY ARE PERMANENTLY LUBRICATED AT THE MANUFACTURING FACILITY Page 27 MAINTENANCE INSTRUCTIONS Table 6 Preventive Maintenance Schedule ACTION rag Pedals and Footstraps Seat Post Locator Pin Crank Inspect Each month or N A Bearings after 300 hours of use Drive Lubricate Each month or Chain after 300 hours of use Clean lubricate j Each month Degreaser Tri Flow M or and adjust 300 5 other spray e in lube 70 hours of use TROUBLESHOOTING e TROUBLESHOOTING GUIDELINES This section outlines several tests to systematically identify and isolate problems with the electrical system and the drive train This troubleshooting section is organized into three basic problem sections Electrical System Console Diagnostics and the Drive Train Perform the tests in exactly the same order as written Refer to the Parts Removal and Replacement section of this Manual for any disassembly and assembly instructions To order a replacement
77. the handlebar 5 Reinstall in the reverse order 3600 RC 1 Remove the console Z Loosen and remove the four nyloc nuts from the mounting flange refer to Figure 12 Page 46 3 4 PARTS REMOVAL AND REPLACEMENT Remove the mounting bolts and flat washers from the frame Hold onto the handlebar with both hands and lift the handlebar console mount off the frame 5 Reinstall in reverse order SEAT 3000 1 Loosen and remove the four mounting bolts and lock washers located underneath the seat refer to Figure 11 2 To reinstall the seat line up the holes in the seat post mounting tab with the holes in the seat Insert one bolt with a lock washer into each hole and tighten securely 3600 RC The seat pads can be removed while the seat is in the seat track Loosen and remove the four mounting bolts from each seat pad and lift the pad free To remove the seat from the seat track t Loosen and remove the nyloc nut from the rear of the seat track Remove the bolt Remove the seat track cover Lift the seat adjustment handle and slide the seat to the rear and off the track To reinstall the seat line up the front guide wheels with the seat track Carefully slide the seat forward while holding up on the seat adjustment handle Install the seat track cover Install the bolt and nyloc nut Securely tighten the nut The seat track play can be adjusted Loosen the nut on both center wheels Use a sta
78. the pedals but not so tight so as to cut off the circulation If you need to adjust the footstrap length get off the bike and stand to one side There are two adjusting holes on the inside footstrap mount and four holes on the outside footstrap mount Most shoes can be accommodated by adjusting the outside mounting holes To make the necessary adjustments grasp the pedal with one hand and the outside end of the footstrap with your other hand Carefully pull the outside end of the footstrap off the tab on the pedal Insert the proper hole of the footstrap onto the pedal tab If you need to make additional adjustments repeat the process with the inside mounting holes of the footstrap Page 3 BASIC OPERATING INSTRUCTIONS THE ATTRACT MODE The console is in the ATTRACT mode when the Spinnaker systems cycle ergometer is idle and ready for use A graphic of a bicycle and a sailboat with a spinnaker scrolls across the display while the Spinnaker systems cycle ergometer is in the ATTRACT mode You can program your own message to scroll across the text bar Refer to the Customizing the Text Bar Scrolling Message section of this Manual for further instructions on program ming your own messages for the ATTRACT mode THE BASIC EXERCISE PROGRAM Once you have properly adjusted the seat and the footstraps you are ready to use your Spinnaker systems cycle ergometer To start the BASIC EXERCISE program simply begin pedaling The ATTRACT mode ends a
79. tic collar with the adjustment pin pulled out Clean the seat post of any accumulated grime with a clean rag The seat adjustment pin should completely engage the holes in the seat post If the seat adjustment pin spring action is sticky apply a few drops of 30W motor oil or Page 26 MAINTENANCE INSTRUCTIONS the equivalent lubricant to the pin shaft Monthly Inspection 1 Inspect the crank bearings for either excessive play or tightness Either condition will reduce the life of the bearings Ensure the bearing clamps are tight Refer to the Part Removal and Replacement section of this Manualfor the proper maintenance and adjustment procedures Lubricate the drive chain with a spray on chain lubricant such as Tri Flow There is a lubrication hole on the right side cover at the nine o clock position in reference to the crank refer to Figure 6 You must use the plastic nozzle exten sion if you lubricate the chain through this hole Insert the nozzle extension into the hole and spray the chain while turning the pedal crank counterclockwise Three revolutions of the crank will ensure lubrication of the entire chain make sure that you do not over lubricate the chain Quarterly Maintenance Clean and thoroughly lubricate the drive chain and adjust the chain tension every three months Follow the chain removal procedures in the Parts Removal and Replacement section Use a degreaser to clean the accumulated grime from
80. to correct the interference at his own expense CHANGES OR MODIFICATIONS TO EQUIPMENT NOT EXPRESSLY APPROVED BY STAIRMASTER SPORTS MEDICAL PRODUCTS INC COULD VOID THE USER S AUTHORITY TO OPERATE THIS EQUIPMENT CANADIAN DOC CLASS A COMPLIANCE This digital apparatus does not exceed the Class A limits for radio emissions from digital apparatus set out in the radio interference regulations of the Canadian Department of Communications La pr sent appareil num rique ne d passe pas les limites etablies pour les bruits radio lectriques applicables aux appareils num riques de la Class A prescrites dans les r glement sur le brouillage radio lectrique dict par le Minist re des Communications du Canada Page 56 OFFICES IN THE UNITED STATES CORPORATE HEADQUARTERS 12421 Willows Road NE Suite 100 Kirkland WA 98034 1800 635 2936 or 206 823 1825 FAX 206 823 9490 HOW TO ORDER PARTS 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 CUSTOMER SERVICE 12421 Willows Road NE Suite 100 Kirkland WA 98034 800 331 3578 or 206 823 1825 FAX 206 814 0601 INTERNATIONAL OFFICES AND DISTRIBUTORS INTERNATIONAL DIVISION 206 823 1825 FAX 206 820 7505 EUROPE HEADQUARTERS 41 92 823801 FAX 41 92 823802 GERMANY HEADQUARTERS 49 2204 610 27 FAX
81. to the machines While the console is in the ATTRACT mode press UP ARROW 1 7 4 6 ENTER and verify the addresses of all the serially linked bikes Each console must have a unique address number within the range 1 to 5 Isolate and test the inoperable Spinnaker 3000 CE Cycle Ergometer 1 Disconnect all serial cables from the inoperable Spinnaker systems cycle ergometer and connect the power supply directly to that machine If the console does not power up perform the power tests as outlined in sections C and D These tests will identify the inoperable component If the console does power up use a serial cable to connect this machine to another bike Continue connecting additional bikes until the original bike fails Use a multimeter to check for continuity through the serial cables at all three pins coming out of and going into the last bike that passed the test refer to Wiring Diagram 4 Replace the inoperable cable s If there is continuity through the serial cables the power supply is probably inoperable Replace or exchange the power supply and retest If the problem still exists contact the Customer Service Department of StairMaster Sports Medical Products Inc Verify AC power 1 Disconnect the AC power cord from the power supply and the AC wall outlet Page 35 2 ELECTRICAL TROUBLESHOOTING SERIALLY LINKED SPINNAKERS Verify that the AC wall outlet is supplying the correct pow
82. vise the Spinnaker systems cycle ergometer whenever it is used by or near children invalids or disabled persons Keep children away from the pedal crank assembly or other similar moving parts A serious injury could result from an infant s or a small child s fascination with the moving components of the exercise machine Keep your hands away from all moving parts and keep your feet firmly planted on the pedals while exercising Do not operate with the side panels removed Use the Spinnaker systems cycle ergometer only for its intended use as described in this Manual Do not use attachments or accessories that are not genuine products provided by StairMaster Sports Medical Products Inc Never operate the Spinnaker systems cycle ergometer if it has a damaged cord or plug if the power is not applied if the console or machine does not appear to be operating properly if it has been dropped or damaged or if the power supply has been dropped into water Call the Customer Service Department of StairMaster Sports Medical Products Inc at 800 331 3578 to arrange for damaged parts to be returned to our manufacturing facility for Page 1 SAFETY GUIDELINES examination and repair International customers may contact their local distributor Do not attempt to use the equipment until all problems have been corrected Connect the power supply to a properly grounded outlet only refer to the grounding instructions section in this Manual
83. wheel for smoothness of operation in the counterclockwise direction and for positive engagement in the clockwise direction Use a freewheel tool to remove the freewheel from the Poly V pulley if replacement is necessary Reverse the steps to reinstall the parts Additionally ensure that The short side of the j bolt hook faces to the rear of the frame The wider portion of the threaded spacer faces to the right You use a new tywrap on the sensor cable and the left side fan shaft bracket Ensure the wires are fully seated in the white plastic connector The magnet mount is as close to the hall effect sensor as it can get while not contacting the hall effect sensor as the fan shaft turns The magnet mount can be up to 1 4 inch 0 6 cm away from the hall effect sensor The fans are installed according to the instructions the Fan section of the Manual e The drive chain is adjusted according to the procedure outlined in the Drive Chain section of this Manual The Poly V belt is adjusted so the distance between the edges of the top and bottom spring retainers on the j bolt is between 1 7 16 and 1 9 16 inches 3 7 4 0 cm refer to Figure 18 FAN SHAFT ASSEMBLY 1 Remove both neck covers 3000 CE only and the side covers Remove both fans Remove the drive chain Loosen but do not remove the nuts at the top and bottom of the intermediate shaft bracket refer to Figure 19 Loosen the j bolt nut so the P
84. ycle ergometer has three major components the power supply the power cables and the console In order to identify the component that is causing the problem you must identify the problem and systematically test the system You will need a Volt Ohm meter multimeter to conduct portions of the following procedures The console and power supply are not servicable by the owner If either of these parts are inoperable they must be replaced Opening the console or the power supply will void the warranty AN WARNING TO REDUCE THE RISK OF ELECTRICAL SHOCK WHEN WORKING WITH AC VOLTAGE A QUALIFIED ELECTRICAL TECHNICIAN SHOULD PERFORM ALL ELECTRICAL TESTS THAT INVOLVE CHECKING AC POWER ELECTRICAL TROUBLESHOOTING WP 1 POWER SUPPLY 3 One Spinnaker Systems Cycle Ergometer With A Wall Mounted Power Symptom The console fails to power up Perform a visual check of the machine Check the following things first 1 2 3 15 the power supply plugged into the AC wall outlet Is the DC cable connected to the machine Replace or exchange your console with a console you know is good and retest the machine Verify AC power 1 2 Unplug the power supply from the AC wall outlet Verify that the AC wall outlet is supplying the correct power in one of two ways a Use an AC voltmeter to verify that the AC line voltage is between 100 and 120 VAC at the AC outlet or b Plug in an alternate AC powered device a l

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