Stairmaster FreeRunner 5400 ESS User manual

FreeRunner™ 5400 SS
Owner's Manual

APPENDIX
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LEG ASSEMBLY PILLOW
BLOCK BEARING
(PN 25247)
LOAD RESISTOR
IPN 25121)
LIMIT SWITCH ASSY
(PN 270021
LEG SPROCKET
(PN 21816·03)
BRAKE MOTOR
(PN 27020)
ALTERNATOR ASSY
W/BRAKE
(PN 22666)
CHAIN LINK
15-,900
(PN 22738·05)
".-- UPPER REAR DRIVE CHAIN
----- #40, 12.5-
(PN 21866)
DETAIL A
LOWER HEEL LINK
CHAIN #40, 12.5-
(PN 21866)
DETAIL A
STRIDE SENSOR
(PN 25112)
HEEL LINK PILLOW
BLOCK BEARING
(PN 21941)
POWER CONTROL BOARD
(PN 25102)
PEDAL RETURN SPRING
IPN 21093)
CHAIN LINK
30.25-
(PN 22740·05)
UPPER FRONT DRIVE CHAIN
#40,24.5-
(PN 21826)
STEP CHAIN
#40,47.5-
(PN 21906)
HEEL LINK
TURNBUCKLE ASSY
(PN 21852)
MOUNTING BLOCK· LOWER REAR DRIVE
LEFT (PN 25304) CHAIN #40. 64S
(PN 21823)
Figure 19: Final Assembly - left Side
" I ••••• , •••• , .:, •• : •• \/.,." ...... ,'11\ ~
• :.' •.. :: ..... :: ..... :.: .. ::~:,.::~::~(:<.':'.J.'~.I.
• ••••• :,", •• :·.· ••••••• ·.I'·:."'.·~IIIe'I).~
· I'.· ," ": \: ./:/.:: .. ~~~ ·/:~,I,'t.'... ~
BUMPER
(PN 284961
LOWER FRONT
DRIVE CHAIN #40,
53.5" (PN 21907)
Page 70

DRIVE SPROCKET
IPN 10382)
STEP CHAIN
#40,47.5"
IPN 21906)
PEDAL RETURN SPRING
IPN 21093)
UPPER HEEL LINK CHAIN
#40, 18.5"
(pN 21905)
LOWER FRONT DRIVE
CHAIN #40, 53.5"
~ IPN 21907)
HEEl LINK PILLOW
BLOCK BEARING
(pN 219411
~ ~"i:';:'":'~~"::·/:":\·.::":.":I": .
W
~Y,I"I''1'''''''''''''''''''' ••••
'l'H ... 1\· .... •• ... •••• It ••••• I" I • •
i<'.'\")}~"'~'.\:::~~~~':'\':'::.:'",:: :;-:.:. "':'::,':' .:
LEG SPROCKET
IPN 21816·031 -
UPPER FRONT DRIVE CHAIN
#40,24.5-
IPN 21826)
DRIVE CHAIN
TURNBUCKLE ASSY
~~'\' IPN 21852)
- MOUNTING BLOCK·
~~~~:::::;;;;r:;~=!J RIGHT (pN 25303)
BUMPER
IPN 284961
LOWER REAR DRIVE
CHAIN #40. 64.5"
IPN 218231
APPENDIX
Page 71
HEEl LINK TURNBUCKLE ASSY
IPN 21852)
DETAIL A
Figure 20: Final Assembly - Right Side
CHAIN LINK 15", 90
0
IPN 22738·05)
HEEl LINK CHAIN #40.5.5"-\-- _____
IPN 20532)
EXTENSION SPRING
IPN 219261
LOWER HEEl LINK CHAIN #40. 12.5"
SEE FIGURE 21
IPN 21866)
UPPER REAR DRIVE CHAIN
#40, 12.5-
IPN 21866)
LEG ASSEMBLY PILLOW
BLOCK BEARING
IPN 25247)
...
...
...
...
...
..
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....

(,Wx~"i',~·r·~'~\':.~;;:·,~·:·::\·:,:"':':" ' .
• ~~~L:'.\)·.~~):·:·:.:~.~:··:'::· .::. '0 :0° ••••••• ' • •
'N.~;' (0,.).",.;1 •• ,., ,..' .' : •
~J ;\lo~ ')/ ,,' ··':.".0· '0 .. 0. to' .'
. ...~ .1'..... ., '\ .. 1... . 0°. .' ••
Figure 21: Chain Assemblies
@CHAIN
140.24.5·
2X PH 21826
DOUBLE PITCH
MASTERUNK
(1)
8X PH 20329
2
®PEOAL RETURN SPRING
2X PN 21D93
@ UPPER HEEl LINK CHAIN
2X PN 2190S
(3)
r
@CHAINLINK
..
IS·, 900
1X PN 22738-oS
...
RIGHT SIDE
® TURNBUCKLE ASSEMBLY
..
3X PN 218S2
...
..
(2)
...
@
...
SPRING
2X PH 22752
...
® STEP CHAIN
@2X
21906
..
CHAINUNK
30.25·
2X PH 22740-D5
...
..
..
® LOWER REAR DRIVE CHAIN
..
- lXPN21907
..
SPRING CHAIN
CONNECTOR
8
2X
PN 2D768
®SPRING CARTRIDGE ASSEMBLY
1X PN 22694
..
CHAIN
14D, 12.S· 3
..
4X PH 21866
evLDWER FRDNT DRIVE CHAIN
1X PH 21823
..
Page 72
APPENDIX

APPENDIX
Page 73
~ ':1":);{I·i.:~::~;;:.::;:'.:.~.: .:: :::::.: ::' :'.' : :. :
'1:\:');;: ~. '.~ , .
~~ J.(',"~'~"~~.'''::::~~~':,\: .. ::.::: ',',":.' .: '.'
INTERMEDIATE POLY·V PULLEY ASSEMBLY
IPN 25216)
Figure 22: Belt Tension
ALTERNATOR ASSEMBLY
WI BRAKE IPN 226661 ~
LOWER POLY·V BELT
(PN 218181

.... "
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::."~~::C
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:::.:.::.::
.......
.. -: .:.";
: ....
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DRIVE SHAFT (;
SPACER N
IPN 22781) ~
SET SCREW ~
IPN 22037) (;
C/)
:::r
=
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en
C'll
3
cr
-
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LOWER POLY·V
PULLEY
IPN 21812)
DRIVE SHAFT KEY
IPN 25183) (2)
~J .~
LEFT SIDE
(8)
11 0)
MOUNTING BLOCK
LEFT SIDE
IPN 25304)
ORIVE SHAFT
IPN 227111
I
(10)
WASHER
® 12 X PN 22222)
r
~ HEEL LINK
~_® IDLER SPROCKET
/ 12 X PN 25249)
/
1
SCREW
12 X PN 25211)
~
MOUNTING BLOCK
~ RIGHT SIDE
r IPN25303)
~(,ffi DRIVE CHAIN
~
® IDLER SPROCKET
II (4 X PN 22640)
\
®WASHER
I (2 X 23739)
®SCREW
(2 X PN 25208)
SCREW
12 X PN 28233) (j)
RIGHT SIDE
THRUST BEARING
14 X PN 201981
SNAP RING @
(2 X PN 20206)
([J) r-(2)
'\
. 0
THRUST J
WASHERS
(8 X PN 20197)
SPROCKET
ASSEMBLY @
(2 X PN 10382)
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::::.
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LEG ASSEMBLY
(PN 25279 . LEFT)
(PN 25280 . RI.GH,T)
LEG SHAFT KEY
(PN 22758)
e3
MOUNTING SCREWS
(4 X PN 22204)
~
BEARING BLOCK
ASSEMBLY
SET SCREW (PN 25197)
(PN 22037) \ ~~~ \ :
~
~ ,
o ~, '
~r\ ,0 O"'~ .\
, 0\\ ,
.\\,
," ~
"LEG SPROCKET, '~'\\ \
(PN 21816·03) '\ \ \~ "
OJ'
,
WASHER ,
(PN 22709·05) ,
SPLIT LOCK
WASHER
(2 X PN 23729)
FLAT WASHER
12 X PN 25253)
WASHER
SPLIT LOCK
(PN 25181)
PILLOW BLOCK ~
BEARING ~ r1\ ~
lPN 2524 7) ~ r
SCREW JAM NUT
(2 X PN 25256) (PN 22708)
"'tJ
C)
(Q
CD
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(J'I

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HEEL LINK ASSEMBLY
IPN 22717·03· LEFT)
IPN 22719·03 . RIGHT)
THRUST BEARING
(2 X PN 22232)
SNAP RING
IPN20213)
THRUST WASHER
14 X PN 25186)
HEEL PIVOT
(PN 22672 . LEFT)
(PN 22673 . RIGHT)
BEARING BLOCK
ASSEMBLY
WASHER
SPLIT LOCK I HEEL PIVOT
(PN 251~81) SPROCKET ~p~A~18~~~
, (PN21892·05) \
PILLOW BLOCK \ ~
BEARING i c:()
IPN 245461 ~ ~ f\ c:()
~~ ~ ~ "\~ IV cfJcfJ
, ~ \
SCREW JAM NUT
(2 X PN 25256) (PN 21932)
SPLIT LOCK WASHER MOUNTING SCREWS
WASHER (PN 21933) (4 X PN 22204)
(2 X PN 23729)
FLAT WASHER
(2 X PN 25253)
-a
Q)
Q
CD
"
0')

APPENDIX
Page 77
(3)
(2)
(4)
/
~ ~"'l';:/ ·~~"::·/:'·:\·.I·:'": I": 1° I" .
~
M"(I,.'I"~"Y':~J":.'""':':" •• ': '. II •••
'~J ~"",<,·;''>:'>~::\::.\:i::,':·:: :':.:: .,'::. •.•.• •
\o..~ \'1 ~I ·"I·\.~·I.\ •••••: •• I.· .. ''''' .. II
Figure 26: Pedal Mounting
WASHER
(2 X PN2187l) 2
SNAP RING
(2 X PN 20213) 1
THRUST WASHER 3
(2 X PN 21937)
SPACER
(2 X PN 2528610

. RIVETS
/ (6 X PN 22086)
~
~
PEDAL STRAP
(PN 21862)
oe
c.~
o0 ~PUSHNUT
FASTENER
(6 X PN 20508)
Figure 21: Pedal Assembly
PEDAL COVER
(PN 21817)
PEDAL SHAFT "OUSING*
(PN 22692)
*INCLUDES PRESSED·IN
BRONZE BUSHING· PN 20002
APPENDIX
PEDAL SUPPORT
(PN 22690)
Pane 78

Page 79
APPENDIX
..
Figure 28: Master Links
DIRECTION OF CHAIN TRAVEl
DIRECTION OF CHAIN TRAVEL
-
DOUBLE PITCH-MASTER LINK IPN 20329)
SINGLE PITCH MASTER LINK IPN 25305)

~~~-- -------~:1.._.Y--_---I::::=::l- - - - - - - - --
APPENDIX
USE THE HEEl LINK TURNBUCKLE TO ADJUST THE TOP
EDGE OF THE HEEl LINK PIVOT ASSEMBLY SO THAT IT
IS PARAUEL TO THE FLOOR
_[.
(,\~. 'W/)";'>~~'\':;':'i"::,,,,,,,,,·:···,, .. ' .
. ~.,~", "', ..... :.... ..... .'
I..... V\·»· .. ··,··· • '. •••••• •
~ ~ (." .'
P,i("~ • ','\, "j. '\'" to'.\ ," ,'. • • ••• '. •
i Ji.. • ~~~t~,'~'::.::\·'.~i:::::'·.·:.:·.: : , : .
Figure 29: Heel Link Pivot Adjustment
. .. .. .. ,. ,." ,.,~.lo.~
. . ' .. :: ...".,., ".'(','V,. ~~.,,>:"(.o.
•• • I "',"' .t •• " ,.... ',y~, •
: . '. '.: .... . ::· ::·:.:::::·:.:::,~·::;::;?j~;tl),~
. I" I''',': •. :,:.,:'.:: .. ;;. '1:.' ,Yo.' ~ I
ALIGN THE TOP EDGE OF THE
PIVOT PARALLEL TO THE FLOOR
Page 80

Figure 30: Handle Assembly
APPENDIX
Page 81
SHOULDER WASHER
(2 X PN 22681)
BOLTS
(2 X PN 22718)
-~
~
SPRING
(PN 25250)
~ HANDLE KNOB PIN
. ~IP"25251.051
HANDLE ASSEMBLY
(PN 25217)
ACORN NUTS
(2 X PN 22716)
tc@
~

MECHANICAL STOPS
'PART OF THE LIMIT SWITCH
ASSEMBLY (PN 27002)
~
~~~(,\'~. '~'¥I)':":"'":;':''''::''''''''''''' .. ' ,.
'I '\ 0\(," "\". , ••••• ". to 00' •• :.' .'
•ItII\ v'\}·.~)\),\: ••••• I' : ••.•• ". 00 •• •• •••••• •
~fw~t;·S~:i:':':~·:,~::·:::·.';·; ;'::; :.':.,' ::,: :',
• ..,-.y;;.:t:,,'I.. .\.' ..... '\ ' •• , ••••• ,•• 1°. •• ••
GREEN WIRE
RED WIRE
+4----iI-----·BRAKE ON' SWITCW
o 0,-+_--+_ 'BRAKE OFF' SWITCW
Figure 31: Limit Switch Assemblv
BLACK WIRE
o
BRAKE ACTUATOR ARM
IPN 22791-05)
APPENDIX
BRAKE CAM
IPN 21840) --+------+---
Page 82

APPENDIX
DETAIL A
~ ~'>'i:"" ~~~"::'/:' ":" 'I::' . : : : .• I" .
p;
~V,II"III~"Y':'''',''''''':':'' .:,' '. .. • • •
I 'lil ',,'): ":::'::.\:i::·':',': :"::. "t·.· I"' •• I '. •
,~=>2 ':. ~A'I),I'" .... ,.,·1\ ,',':1·. .... •
.1 .... nl'·'\,. • ••• •••
Page 83
Figure 32: Power Control Board I' AU
LIMIT SWITCH ASSEMBLY
(PN 27002) PlUG·IN
LOAD RESISTOR
W/CABLE (pN 25121)
PLUG·IN
FREERUNNER POWER CONTROL BOARD IPN 25102)
--

LED PANEl
"OW if the power supply is operating. If "OFF", chock the following:
wall outlet, power supply, power connoctor. and power control board.
"OW if power is getting to the console. and if the console is
providing +SV back down to the power control board. If "OFF", chock the
following: upper and lower main cable, console. and power control board.
"OW if the console is disabling the alternator (as in the
AnRACT mode), "OFF" when the alternator is turned ON (as in an exercise
program). Inspoct the console, alternator cable. alternator and power control
board if the LED is not functioning properly.
POWER CONTROL BOARO - LIGHT EMmlNG DIODES (LEOs)
#3- All Off-
#1 -vSIPPIy-
Figure 33: LED Pinel
APPENDIX
--AT REST. WITHOUT ANYONE ON THE MACHIIiE. NIIiE LEnS SHOUW BE 0" ....
12- vee-
#4 - Lad Resist.r- "OW when the main load resistor is OFF. Have an assistant exercise on the
machine while you watch the LED. Start at intensity level 1 on the console and
continue through level 20. The LED will fade out as you increase intensity. If
the LED does not function properly. chock the main cable and power control board.
#5 -Stride Sens.r- "OW when the pedals are aligned. If "OFF", ensure that the pedals are aligned
and chock the stride sensor magnet position (see page 63). Also chock the stride
sensor board, stride sensor cable, and power control board.
#6 -MotorDir- "OW indicates that the brake will be engaged when cycled, "OFF" indicates that
the brake will be disengaged when cycled (see "Brake Test", page 35).
17 -Motor On 0 "OW when the brake motor is OFF. "OFF" when the brake motor
is driving the brake to ON or OFF (see "Brake Test", page 35).
#8 - UL "Brake 0."0 "OFF" when the brake motor is driving the brake to ON, until the
limit switch is contacted (see "Brake Test", page 35).
#9 - LL "Brake Off" - "OFF" when the brake motor is driving the brake to OFF. until the
limit switch is contacted (see "Brake Test", page 35).
#10 -Nat Used - _ This LEB should never be on. Inspect the power control board if it is on.
Page 84

Figure 34: Power Control Board "B"
Pins:
1
2
3
4
5
6
7
8
9
10
~ ~'i';:'" ~~~ .. :: ... :/ :.' I.::.. ::: .': .
.' ~~"<I~III~"Y':'"I"·"".'·:" to to': ' ••••••
'iN ',:.').: "':::~::.\:i::":·.·: :::: .... :: .. '. '. .
~=>.: • .:'/,Y"I{ • '~/'\1 ...... \."." .• " • ".. •
~;;: "t. I • ................
APPENDIX.
Page 85
CONSOLE PLUG-IN
(On the PCB Board)
Pin 1- Alt Off
Pin 2-V Supply
Pin 3- B+ Scaled
Pin 4 - Resistor Control
Pin 5- VCC
Pin 6- N/C
Pin 7- Tach
Pin 8- N/C
Pin 9- Stride Sensor
Pin 10- Ground
.. .. . . .. , .. \ ..... ,.\. '\\1:/..,,' RII:\t..'\!!JII~j"
. " :'.',':",'.': :.: :::':~:~'::,':.::~'~.~:.:i::~.~/'.~~)'~}P; ,. Wl~"''' tiJf.
'. . ..... ...· .... ··.··:'I' .. ··:!~ ... S\,.'L<.~~ I ~~~~/1~
• • • • to • '. '.:. ::. ·.:::·:·::'.::.:.~ •• :~~:/~~~'~~"<'if:~,)(~\~ .;~~J

789
YIEW B· B
Pin 1 - BLK V-Supply
Pin 2- BROWN Ait Off
Pin 3 - RED B+ Scaled
Pin 4- ORG Resistor Control
Pin 5- YELLOW vee
Pin 6- GRN Ta:h
Pin 7. BLU Grouoo
Pin 8 - VIO Stride Sensor
Ping -NIt
1 2 3
CONSOLE MAIN CABLE
Figure 35: Console Main Cable
L~J
3 2 1
000
6
000
4
000
r~l
987
VIEW A· A
\~
Page 86
--
APPENDIX

APPENDIX
Page 87
4
ALTERNATOR CABLE
Pin 1-Bt (White ~ire)
Pin 2- Ground (Black WI~e)
Pin 3- Field (Brown YVlre)
Pin 4- Tach (Blue Wire)
DIODE
Figure 36: Alternator Cable
A
J
II
VIEW A. A
1 2 ~ 4
~[9J[9J~
A
L
-

Pin 1•V Supply
Pin 2- Ground
Pin 3- Earth Ground
POWER SUPPLY
Figure 37: Power Supply
Pins:
1
2
3 ~:::t'
APPENDIX
Pane 88