Instruction/ maintenance manual of the product 4600 PT/CL Stairmaster
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F REE C LIMBER 4200 PT , 4400 PT/CL, AND 4600 PT/CL O WNER ’ S M ANUAL ®.
© 2001 StairMaster Health & Fitness Products, Inc. StairMaster and FreeClimber are registered trademarks or trademarks of StairMaster Health & Fitness Products, Inc. in the United States and/or other countries. All other trademarks are trademarks of their respective companies.
Page iv WARRANTY This is to certify that the StairMaster ® FreeClimber ® exercise system is warranted by StairMaster Health & Fitness Products, Inc. to be free of all defects in materials and workmanship. This warranty does not apply to any defect caused by negligence, misuse, accident, alteration, improper maintenance, or an “act of God.
Page v PREFACE Regular use of the StairMaster ® FreeClimber ® exercise system is a safe and effective way to develop aerobic fitness while conditioning the major muscles of the lower body . T o get the best results, and to keep your machine in peak operating condition, you should carefully read and follow the guidelines presented in this manual.
Page vi CONTENTS SAFFETY GUIDELINES ........................................................................................ 1 INTRODUCTION ................................................................................................... 3 INST ALLA TION INSTRUCTIONS .
Page vii CONTENTS The Fitness T est Programs ................................................................... 2 4 Understanding Submaximal Exercise T esting .................................... 2 4 Pretest Screening ................................
Page viii Diode T est ....................................................................................... 4 6 Resistor T est ................................................................................... 4 6 4600/4400 CL: ....................
Page ix First Reduction Shaft Assembly .................................................................. 6 6 Handlebar (4400 PT/CL, 4200 PT) ............................................................... 6 6 Upper Handles (4600 PT/CL) ..............
Page x Figure 12: Final Assembly - Left, 4600 PT ................................................... 7 5 Figure 13: Final Assembly - Right, 4600 PT ................................................. 7 6 Figure 14: Final Assembly - Left, 4600 CL .......
Page 1 W HEN USING ELECTRICAL EQUIPMENT , ALWAYS FOLLOW THESE BASIC PRECAUTIONS : IMPORTANT SAFETY INSTRUCTIONS This symbol appearing throughout this manual means Attention! Be Alert! Y our safety is involved.
Page 2 4. Use this machine only for its intended use as described in this Manual. Do not use parts, attachments, or accessories other than those provided by StairMaster ® Health & Fitness Products, Inc.
Page 3 Before leaving the manufacturing facility in T ulsa, Oklahoma, your StairMaster ® FreeClimber ® exercise system was thoroughly inspected and tested to ensure proper operation.
Page 4 Figure 2: Major Parts - 4200 PT and 4400 PT/CL INTRODUCTION.
Page 5 Throughout this Manual, all references to the left or right side and to the front or back are made as if you were on the machine, ready to exercise. For example, the console is located on the front of the machine. The dimensions and general specifications of the machines are listed in T able 1.
Page 6 Assemble your machine before use. Machines shipped outside the United States need to be uncrated before they can be assembled; refer to the “Uncrating Instructions” included with your machine for the details. 1. Remove all shipping material from your machine once it is in place.
Page 7 4. If you have a 4600/4400 CL, skip to step 9. If you have a 4600/4400/ 4200 PT , connect the DC cable of the power supply to the connector near the bottom of the left side cover (see Figure 4). Figure 4: DC Power Connector 5. Place the power supply on the floor near an AC wall outlet.
Page 8 6. Check to be sure that the input AC power rating marked on the power supply matches the available power . If it does not, obtain the match- in g power supply from StairMaster ® Health & Fitness Products, Inc. before proceeding any further .
Page 9 GENERAL GUIDELINES FOR SAFE OPERA TION 1. Obtain a complete physical examination from your medical doctor and enlist a health/fitness professional’ s aid in developing an exercise program suitable for your current health status.
Page 10 YOUR FIRST WORKOUT ON THE ST AIRMASTER ® FREECLIMBER ® EXERCISE SYSTEM 1. Warm up with light calisthenics and easy stretching exercises for at least five minutes before beginning your exercise program. 2. Hold onto the handlebars and step up onto the pedals.
Page 11 program starts at level three. 8. As you become comfortable with exercise motion, press [LEVEL: ∧] and [LEVEL: ∨] to adjust your climbing speed. 9. Relax and stand up straight while exercising. Use the handlebars for balance (see Figure 5).
Page 12 Head - Keep your chin parallel to the floor . Avoid staring at your feet or the computer console. This posture will also enhance your breathing. B ack - Although the whole body is in a slightly forward slant, keep your back straight and avoid bending at the waist.
Page 13 HEART RA TE MONITORING HEART RA TE INPUT Contact heart rate and telemetry (e.g., Polar ® ) heart rate signal detection is available. There is no default priority of heart rate input.
Page 14 HEART RA TE MONITORING 2. There are four options to handle heart rate input signals. Press the [SELECT] key to scroll through the options until you find the one option that suits your needs. Press the [ENTER] key to select that option. “ BOTH HR ON “ - allows either telemetry or contact heart rate signals to be detected.
Page 15 “ HOLD HR SENSORS ” - In contact heart rate signal situations this message will come every 30 seconds to prompt the user to hold the sensors. “ HR MODE DISABLED ” - No heart rate signal is allowed due to the set up option that was chosen.
Page 16 contact heart rate signals. If you do not see a heart rate on the console, try one of the following: • Move closer to the console. • T ighten the elastic part of the chest belt. • Adjust the belt higher or lower on your chest. • Remoisten the electrodes.
Page 17 CONT ACT HEART RA TE The StairMaster ® FreeClimber ® 4600 PT/CL features a digitized contact heart rate monitoring system. Through the use of stainless steel sensors built into the upper handles and sophisticated software, heart rate can be checked at any time during a workout.
Page 18 The StairMaster ® FreeClimber 4400/4600 PT/CL systems console is divided into seven sections: the display window , the workout options, the numeric key- pad, the entertainment keypad, the workout statistics, the stop key , and the intensity level keys (see Figure 7).
Page 19 NUMERIC KEYP AD The numeric keypad is located on the right side of the con- sole. Before the exercise program begins, the numbers are used to enter data in response to the console prompts. • Enter - Confirms workout selections and stores the informa- tion used by the console to calculate workout statistics.
Page 20 WORKOUT ST A TISTICS During the exercise program, the Stats keys are used to track workout statis- tics which are then shown in the display window . Pressing the [SELECT] key turns off the scanning feature and shows the statistic of choice in the display window .
Page 21 EXERCISE PROGRAM KEYP AD The exercise keypad is located below the display and to the left of the function keypad. While the console is in the “ SELECT WORKOUT ” mode, press one of the exercise program keys to preview the desired workout.
Page 22 on the selected intensity level, with 2 levels equating to one vertical bar . The Fat Burner Program The Fat Burner program is a 60-interval workout designed for people just starting a weight control program.
Page 23 the intensity level during an EXERCISE interval. The intensity level shown dur - ing an EXERCISE interval is indicative of your current speed. However , the cur - rent speed during a REST interval is equal to a scaled percentage of the dis- played intensity level.
Page 24 FREECLIMBER 4400/4600 PT/CL CONSOLE THE FITNESS TEST PROGRAMS Understanding Submaximal Exercise T esting Before using the StairMaster ® FreeClimber ® for submaximal exercise testing, it should be noted that all submaximal fitness tests make several assumptions: • That a steady-state heart rate is obtained for each exercise workload.
Page 25 FREECLIMBER 4400/4600 PT/CL CONSOLE 150, external factors no longer influence heart rate, and a linear relationship exists. As the heart rate rises above 150, the heart-rate/oxygen uptake rela- tionship becomes curvilinear . The third assumption involves maximal heart rate.
Page 26 submaximal exercise tests and that person ’ s heart rate response to a fixed workload is found to decrease over time, it is reasonably safe to conclude that the individual has made improvements in aerobic (cardiorespiratory) fitness, irrespective of the accuracy of the VO 2 max prediction.
Page 27 state heart rate of the subject to 110 to 150 beats/min for two consecutive stages. It is important to remember that two consecutive heart rate measure- ments must be obtained in the 110 to 150 beats/min range to predict VO 2max . The test typically lasts from 9 to 15 minutes.
Page 28 Figure 8: StairMaster ® Fitness Protocol Fir st W ork Level 4 M ETs I f 100 <= HR <= 120 If H R < 10 0 If H R > 12 0 Sec ond W or k Le ve l 7 M ETs Sec ond W or k Le ve l 6 M ETs .
Page 29 T able 2. Fitness Rating Norms (VO 2max ) MEN A g e High Good Average Fair Low 20 – 2 9 >51 5 1 – 47 47 – 43 42 – 4 0 <39 30 – 3 9 >50 5 0 – 45 45 – 41 41 – 3 7 <37.
Page 30 intervals at an intensity of 68 steps/min. The CP A T Stair Climb T e s t has a total of 10 intervals and lasts for 3 minutes, 20 seconds (including warmup). T urning on the CP A T Stair Climb T est 1. Press [ ∧ ], [9], [1], [ENTER], on the console keypad.
Page 31 CONSOLE CODES There are three groups of console codes which are differentiated according to function. The first group of codes are customization codes and are used to set defaults such as units, language, heart rate input type, etc.
Page 32 2. Change the units to either Metric or USA units by pressing [LEVEL: ^], [3], [1], [ENTER]. The console will display the current units - either “ USA UNITS ” or “ METRIC UNITS. ” Use the [SELECT] key to change option, and then press [ENTER].
Page 33 [SELECT] “ CONTRAST ADJ ” 5 [SELECT] “ MAX SPEED ” - N/A- 6 [SELECT] “ CLINICAL MODE ” - N/A -7 [SELECT] “ SET DEF AUL TS “ 9 Machine Status Codes [ ^ ] [ 4 ] [ 0 ] display mac.
Page 34 Quick Scan Programming Y ou can quickly access any of the custom menus by pressing [LEVEL: ^], [4], [ENTER]. The console will then display “ MACHINE ST A TUS.
Page 35 The StairMaster ® FreeClimber ® 4200 PT console is divided into two LCD display windows. There is a four -function keypad located below the bottom window (see Figure 9). While you are exercising, the bottom window scrolls through a display of four workout statistics.
Page 36 FREECLIMBER 4200 PT CONSOLE corresponds to Steady Pace, "P3" to Fat Burner , and "P4" to Aerobic T raining. The different workout option profiles are shown on the right side of the console. 3. When the correct workout option is displayed on the top LCD window , press [ENTER/SELECT].
Page 37 BOTTOM WINDOW The bottom LCD window keeps track of four different statistics during your workout: the number of calories burned, the climbing speed in steps per minute, the total number of floors climbed, and the total distance covered.
Page 38 ST ART/STOP . Press this key while the console is in the A TTRACT mode to begin the workout setup. If pressed at any time during workout setup, all entries are cleared and workout setup starts over again. If pressed during a workout, a 30-second rest period is started.
Page 39 HELPFUL HINTS Read all maintenance instructions thoroughly before beginning work. In some cases, an assistant is required to perform the necessary tasks. All references to the right or left side and to the front or back are made as if you were on the machine ready to exercise.
Page 40 The 4200 PT console keeps track of the number of hours the machine was used and the total number of floors climbed. From the A TTRACT mode, press [+ ARROW] and then double-click [RESET]. The hours are shown in the top LCD window and the total floors are shown in the bottom LCD window .
Page 41 2. Inspect the Poly-V belt and HTD belts for excessive wear during the quarterly lubrication. Adjust the belt tension if necessary . Lubrication There are nine components that need periodic lu.
Page 42 7. Remove the spring pulleys every three months. Clean the spring pulley shafts with a dry cloth. Protect the shafts from corrosion with a thin coat of multi-purpose grease before reassembling. 8. Remove the pedals every three months. Clean the pedal shaft and leveling arm pin with a dry cloth.
Page 43 MAINTENANCE INSTRUCTIONS T able 3: Recommended Preventive Maintenance Schedule *Note: Use of lubricants other than those specified will result in diminished performance and a shorter life span for that part.
Page 44 GENERAL TROUBLESHOOTING GUIDELINES This troubleshooting section is organized into three basic problem sections: electrical troubleshooting, console diagnostic tests, and mechanical trouble- shooting. Once you have identified the problem section, perform all the tests in the same order as written.
Page 45 5. Follow the white power connector wire to the where it plugs into the main cable white wire, and disconnect it from the main cable white wire.
Page 46 • Place a short wire with alligator clips on the B+ terminal and the field (FLD) terminal of the alternator . • Step on the machine for approximately 10 to 15 seconds. • If full resistance is achieved during this time, your alternator has correct current flow .
Page 47 3. Step up on the machine. With the voltmeter set to DC voltage, test for greater than 6.1 VDC in pins #1 (+) and #10 (-) in the main cable connector while stepping. Replace the main cable if the voltage reading is less than 6.1 VDC. Next, check for continuity in the main cable (see Final Assembly Figure).
Page 48 The following tests are performed while the console is in the “ SELECT WORKOUT ” mode. If the console fails any test, the console should be replaced or exchanged. T o return to the “ SELECT WORKOUT ” mode, press either [CLEAR] or [ST ART/STOP] while in the DIAGNOSTIC mode.
Page 49 1. Press [ LEVEL: ^ ], [ 6 ], [ 1 ], to start the test. 2. Firmly press each button except [CLEAR]. The name of the key will be shown in the display window . Press [CLEAR] to end the test. Serial Port T est This test verifies that the RS 232 port used for linking to external C.
Page 50 T ach T est If you do not have resistance, perform the tach test. The tach test will tell you the tach signal, in revolutions per minute (RPMs), picked up by the console. 1. Press [ LEVEL: ^ ], [ 6 ], [ 6 ], [ENTER]. The console will display “ T AR T ACH ACT .
Page 51 Contact Heart Rate T est The contact heart rate system is made up of the console and the contact heart rate sensor handles. Remember that even when operating properly , the contact Heart Rate system will not work for everyone.
Page 52 T elemetry (Polar ® ) Heart Rate T est The telemetry heart rate system is made up of the console, the heart rate re- ceiver , and the chest strap (available separately). Y ou can test each compo- nent by performing the following steps: 1. Y ou will need to put a chest strap on to test the telemetry heart rate.
Page 53 If you hear a grinding or clicking noise, experience excessive vibration during exercise, or if the pedals are not functioning properly , you probably have a problem in the drive train. Attempt to isolate the problem area by performing the following tests in precisely the order listed below .
Page 54 • Do not reinstall the Poly-V belt if performing step #4. Plug in the connector at position J4 or reconnect the DC power cable, as applicable. 4. Remove the drive and step chains. Check the condition of the chains by flexing each link up and down.
Page 55 • Clean all corrosion off the pedal arm shaft and leveling arm shaft a n d bushings. Wipe the shafts with an oil-dampened cloth before reassembling. DO NOT SAND THE PEDAL ARM SHAFT OR LEVELING ARM SHAFT . 9. Remove the HTD belt. Inspect the belt, the Poly-V pulley , and the HTD pulley for excessive wear .
Page 56 COVERS There are three covers on the 4400 PT/CL and the 4200 PT : the top cover , the mid-cover and the bottom cover . The top and bottom covers are made of a right and left section. Do not separate the right and left sections of either the top or bottom covers to perform most maintenance tasks.
Page 57 3. 4600 PT/CL : Use the fastener removal tool to release the cover fasteners and separate the top covers. 4. T o reinstall the 4400 PT/CL and 4200 PT fasteners, remove the pin completely from the base. Insert the base into the hole in the covers.
Page 58 CONSOLE 1. Remove the four mounting knobs from the back of the console. 2. Disconnect the main cable, contact heart rate cables (4600 PT/CL), a n d Polar ® cable (4600/4400 PT/CL) from the back of the console. Lift the console off the machine.
Page 59 6. Adjust the HTD belt tension so that you have 1/4 inch (0.6 cm) of side- to-side play with fingertip pressure (see Figure 30). The bottom shaft is mounted in an eccentric hub. T o adjust the tension: • Loosen and remove the four bolts and nyloc nuts from the hub.
Page 60 4. Check to ensure that the spring pulley turns freely and is not worn excessively . Refer to the “ Spring Pulley ” section if you have to replace the pulley . 5. T o reinstall the spring, connect it to the end of the step chain using the master link.
Page 61 SPRING PULLEY 1. Remove the bottom cover . 2. Unhook the pedal arm return spring from the spring hanger . 3. Remove the snap ring from the pulley shaft (see Figure 11). 4. Slide the pulley and washer off the shaft. 5. Before reinstalling the pulley , clean the pulley shaft thoroughly with a clean, dry cloth.
Page 62 TO REDUCE THE RISK OF EYE INJURY , WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS. ! WARNING 2. Remove the master link from the drive chain. 3. Remove the drive chain from the sprockets. 4. Reinstall the drive chain, ensuring the master link is properly installed.
Page 63 5. Remove the drive chain. 6. Remove the sprocket and the other small parts from the left side of the hub assembly (see Figure 18). 7. Slide the drive shaft to the right, out of the hub assembly . If you remove the right-hand clutch sprocket from the drive shaft, do not confuse it with the left-hand clutch sprocket.
Page 64 PEDAL 1. Remove the snap ring and flat washer from the leveling arm pin and the pedal shaft (see Figure 17). 2. Slide the pedal off the shaft. 3. Clean the pedal shaft and leveling arm pin with a dry cloth. Lubricate the pedal shaft and the leveling arm pin with a thin coat of multi- purpose grease.
Page 65 PEDAL ARM 1. Remove the pedal and the bottom cover . 2. Remove the step chain retainers. 3. Support the pedal arm. Unhook the pedal arm return spring from the spring hanger . Lift the step chain up and off the clutch sprocket and lower the pedal arm to the floor .
Page 66 P ARTS REMOVAL AND REPLACEMENT ECCENTRIC HUB ASSEMBL Y 1. Remove the bottom cover . 2. Remove the Poly-V and HTD belts. 3. Loosen and remove the four nyloc nuts and bolts from the hub. Remove the assembly from the frame. 4. Reassemble in the reverse order .
Page 67 UPPER HANDLES (4600 PT/CL) 1. Disconnect the left and right contact heart rate cables from the back of the console. 2. Remove the two mounting screws from the top and bottom shield and remove the shields from the upper handle assembly . 3. Remove the four handrail adapter screws from the upper handle assembly .
Page 68 P ARTS REMOVAL AND REPLACEMENT 5. T ilt the machine forward and use an extended socket to remove the two handrail adapter screws from the front leg of the machine.
Page 69 The machine must be grounded if you are using the external power supply or the battery charger . Grounding provides the path of least resistance for the electric current, thereby reducing the risk of electric shock.
Page 70 This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
Page 71 APPENDICES If you need assistance, please have both the serial number of your machine and the date of purchase available when you contact the appropriate StairMaster ® Health & Fitness Products, Inc.
Page 72 BA TTERY RECYCLING After installing a new battery , Contact the nearest Y uasa-Exide, Inc. recycling center from the list below to get information on the proper disposal of your old lead-acid battery . Most federal and state regulations require lead-acid batter - ies be recycled.
Page 73 ST A TE ADDRESS PHONE NUMBER New Jersey 131 Industrial Ave. (201) 641-5900 Hasbrouck Hgts., NJ 07604 New Y ork 26 Corporate Circle (315) 437-1788 E. Syracuse, NY 13057 Ohio, Central Rickenbacker ANG (513) 851-3838 Bldg. 1073 Columbus, OH 43217 Ohio, North 2635 Hamilton Ave.
Page 74 APPENDICES Figure 11: Parts Needing Periodic Maintenance.
Page 75 APPENDICES Figure 12: Final Assembly - Left, 4600 PT.
Page 76 APPENDICES Figure 13: Final Assembly - Right,4600 PT.
Page 77 APPENDICES Figure 14: Final Assembly - Left, 4600 CL.
Page 78 APPENDICES Figure 15: Final Assembly - Right, 4600 CL.
Page 79 APPENDICES Figure 16: Covers - 4600 PT/CL.
Page 80 APPENDICES Figure 17: Pedal Arm Assembly & First Reduction Shaft Assembly (4600/4400 PT/CL, 4200 PT).
Page 81 APPENDICES Figure 18:Drive Shaft Assembly & Eccentric Hub Assembly (4600/4400 PT/CL, 4200 PT).
Page 82 APPENDICES Figure 19: Final Assembly - Left, 4400/4200 PT.
Page 83 APPENDICES Figure 20: Final Assembly - Right, 4400/4200 PT.
Page 84 APPENDICES Figure 21: Final Assembly - Left, 4400 CL.
Page 85 APPENDICES Figure 22: Final Assembly - Right, 4400 CL.
Page 86 APPENDICES Figure 23: Covers - 4400 PT/CL, 4200 PT.
Page 87 APPENDICES Figure 24: Cover Removal.
Page 88 Figure 25: Cover fasteners APPENDICES.
Page 89 APPENDICES Figure 26: Drive Chain tensioning.
Page 90 APPENDICES Figure 27: Belt T ension.
An important point after buying a device Stairmaster 4600 PT/CL (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Stairmaster 4600 PT/CL yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Stairmaster 4600 PT/CL - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Stairmaster 4600 PT/CL you will learn all the available features of the product, as well as information on its operation. The information that you get Stairmaster 4600 PT/CL will certainly help you make a decision on the purchase.
If you already are a holder of Stairmaster 4600 PT/CL, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Stairmaster 4600 PT/CL.
However, one of the most important roles played by the user manual is to help in solving problems with Stairmaster 4600 PT/CL. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Stairmaster 4600 PT/CL along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
