Stairmaster FREECLIMBER 4400 PT/CL User manual

FREECLIMBER
4200 PT, 4400 PT/CL,
AND 4600 PT/CL
OWNER’SMANUAL
®

© 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.
StairMaster is a Rutledge Capital Company
P/N 22867-A
Printed in the United States.
© 2001 StairMaster® Health & Fitness Products, Inc.
All rights reserved.
Corporate Headquarters
12421 Willows Road N.E., Suite 100
Kirkland, WA 98034
[phone]
[phone]
Fax [phone]
www.stairmaster.com
Page iii

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
andworkmanship.Thiswarrantydoesnotapplytoanydefectcausedbynegligence,
misuse, accident, alteration, improper maintenance, or an “act of God.” This warranty
isnon-transferablefromtheoriginal owner.
If,withinthreeyearsfromthedateofpurchase,anypartoftheStairMaster
FreeClimberexercise system shouldfailtooperate properly(exceptanyaccessoriesor the
batteryon the 4600 CL and the4400 CL), contact our Customer ServiceDepartment to
report the problem. When calling, please be prepared to provide the customer service
representativewiththefollowinginformation:
• Your name, customer number, shipping address,andtelephonenumber
• Themodel and serial numberof the inoperable machine
• Thedate(s)of purchase for the inoperable machine(s)
• Your billing address
Thisinformationwillensurethatyouarethe only one ordering parts under your
warrantyprotection.If warranty replacement parts are shippedtoyou,youmaybe
required to return the inoperable parts. To facilitate this process, the following policy
has been established:
• Please call our Customer Service Department to receive a Return
Material Authorization (RMA) prior to shipment.
• StairMaster Health & Fitness Products, Inc. will incur all freight
charges for warranty parts ordered for a machine that is less than 45
days old. The parts will be shipped to you via an overnight courier.*
• You are responsible for freight charges on warranty parts for
machinesthatare more than 45 days old.You will notberesponsible
forthereturnshipment of the inoperable parts.
• Someinoperablewarrantypartsmustbe promptly returned to our
CustomerServiceDepartment. Wewillpaytheshippingcost for the
inoperablewarrantyparts.Detailedinstructionsare includedwith
eachwarrantyreplacementpart.
StairMaster Health & Fitness Products, Inc. neither makes, assumes, nor
authorizes any representative or other person to make or assume for us, any other
warranty whatsoever, whether expressed or implied, in connection with the sale,
service, or shipment of our products. We reserve the right to make changes and
improvements in our products without incurring any obligation to similarly alter products
previously purchased. In order to maintain your product warranty and to ensure the safe
and efficient operation of your machine, only authorized replacement parts can be used.
This warranty is void if parts other than those provided by StairMaster Health & Fitness
Products, Inc. are used.
*Note:Aerosolproducts cannot be transported via air.

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. To get the best results, and to keep your machine in peak
operating condition, you should carefully read and follow the guidelines
presented in this manual.
WHAT IS IN THIS MANUAL?
The first part of this manual includes sections on safety, installation, operating
instructions, and preventive maintenance. The second part contains detailed
information on problem troubleshooting and repair procedures. An Appendix at
the end of the manual provides additional information for the owner.
Throughout this manual, console keypad keystrokes are enclosed in [ ].
The names of the keys and special console operational modes are shown in
capital letters. For example, your machine is ready to use when the console
displays "SELECT WORKOUT." Press [MANUAL] to start the MANUAL exercise
program.
WHAT IS THE STAIRMASTER FREECLIMBER EXERCISE SYSTEM?
The StairMaster FreeClimber exercise systems are vertical climbing machines
with an independent step action. The independent step action, combined with
the patented pedal geometry featured on all StairMaster steppers, provides an
aerobic workout equivalent to uphill running or climbing stairs, but without the
high-impact pounding to the joints and muscles.
There are five FreeClimber models: the 4600 PT (Personal Trainer),
the 4600 CL (Cordless), the 4400 PT, the 4400 CL, and the 4200 PT. All
FreeClimbers feature the Quiet Drive transmission. The 4600 PT and the
4600 CL have an adjustable tilting, full-featured Liquid Crystal Display (LCD)
console. The 4400 PT and the 4400 CL have an upright, rail-less design. The
4600 PT and the 4400 PT use an external power supply that is plugged into an
AC wall outlet. The 4600 CL and the 4400 CL use power generated during a
workout to run the electronics. The 4600 PT and 4600 CL have contact heart
rate and telemetry (Polar®) heart rate monitoring. The 4400 PT and the 4400 CL
feature telemetry heart rate monitoring. The 4200 PT uses an external power
supply and the console has less feedback and fewer workout programs than
the 4600 PT/CL and the 4400 PT/CL.

Page vi
CONTENTS
SAFFETY GUIDELINES ........................................................................................ 1
INTRODUCTION ................................................................................................... 3
INSTALLATION INSTRUCTIONS........................................................................ 6
BASIC OPERATING INSTRUCTIONS ................................................................ 9
General Guidelines for Safe Operation........................................................... 9
Your First Workout......................................................................................... 10
Begin Exercising................................................................................... 10
Rest Periods.......................................................................................... 11
Cool Down............................................................................................. 11
HEART RATE MONITORING ............................................................................ 13
Heart Rate Input ........................................................................................... 13
Locked/Non-locked Option.......................................................................... 13
Error Messages ............................................................................................ 14
TELEMETRY HEART RATE (4400/4600 PT/CL ONLY) .................................. 15
Using the Transmitter Belt ........................................................................... 15
Maintaining the Transmitter Belt ................................................................ 16
CONTACT HEART RATE.................................................................................... 17
Using Contact Heart Rate ............................................................................ 17
FREECLIMBER 4400/4600 PT/CL CONSOLE.................................................. 18
Display Window ........................................................................................... 18
Numeric Keypad........................................................................................... 19
Entertainment Keypad................................................................................. 19
Intensity Level Keys .....................................................................................19
Stop Key ....................................................................................................... 19
Workout Statistics........................................................................................ 20
Exercise Program Keypad............................................................................ 21
The Quick Start Program ...................................................................... 21
The Manual Program ........................................................................... 21
The Fat Burner Program ....................................................................... 22
The Aerobic Training Program ............................................................. 22
The Speed Intervals Program .............................................................. 22
The Constant Heart Rate Program ...................................................... 23

Page vii
CONTENTS
The Fitness Test Programs...................................................................24
Understanding Submaximal Exercise Testing .................................... 24
Pretest Screening................................................................................. 26
The StairMaster®Submaximal Fit Test............................................... 26
The Firefighter's Stair Climb Tests....................................................... 29
Turning on the C.P.A.T. Test...........................................................30
Turning on the NYCFD Test ........................................................... 30
Console Codes ............................................................................................. 31
Custom Codes ...................................................................................... 31
Quick Scan Programming ..............................................................32
Machine Status Codes ........................................................................33
Quick Scan Programming ..............................................................34
Configuration Code .............................................................................. 34
FREECLIMBER 4200 PT CONSOLE ................................................................. 35
Top Window..................................................................................................35
Workout Setup...................................................................................... 35
Timer...................................................................................................... 36
Bottom Window ...........................................................................................37
Keypad.................................................................................................. 37
Quick Start Option ........................................................................................38
MAINTENANCE INSTRUCTIONS .................................................................. 39
Helpful Hints ................................................................................................. 39
Tool List.........................................................................................................39
Maintenance Records ................................................................................. 39
Initial Service ................................................................................................ 40
Preventive Maintenance ............................................................................. 40
Cleaning................................................................................................ 40
Inspecting .............................................................................................40
Lubrication ............................................................................................41
Battery Charge...................................................................................... 42
Battery Disposal ...................................................................................42
TROUBLESHOOTING ........................................................................................ 44
General Troubleshooting Guidelines...........................................................44
Electrical Troubleshooting ...........................................................................44
4600/4400 PT: ...................................................................................... 44
Alternator Test ............................................................................... 45

Page viii
Diode Test....................................................................................... 46
Resistor Test................................................................................... 46
4600/4400 CL: ...................................................................................... 46
Battery Test .................................................................................... 46
Alternator Test ............................................................................... 47
Resistor Test................................................................................... 47
Display Test........................................................................................... 48
Keypad Test.......................................................................................... 48
Serial Port Test...................................................................................... 49
Alternator Test ...................................................................................... 49
Tach Test............................................................................................... 50
Error Reporting...................................................................................... 50
Contact Heart Rate Test....................................................................... 51
TelemetryHeart Rate Test.................................................................... 51
Mechanical Troubleshooting....................................................................... 53
PARTS REMOVAL AND REPLACEMENT ....................................................... 56
Covers........................................................................................................... 56
Mid Cover ............................................................................................. 56
Top Cover .............................................................................................. 56
Shield (4600 PT/CL )............................................................................. 57
Bottom Cover........................................................................................ 57
Console......................................................................................................... 58
Console Adjustment (4600 PT/CL) .............................................................. 58
Poly-V and HTD Belt ..................................................................................... 58
Step Chain Retainer..................................................................................... 59
Pedal Arm Return Spring .............................................................................59
Step Chain.................................................................................................... 60
Spring Pulley................................................................................................. 61
Drive Chain ................................................................................................... 61
Drive Shaft Assembly................................................................................... 62
Pedal ............................................................................................................. 64
Leveling Arm................................................................................................. 64
Pedal Arm...................................................................................................... 65
Pedal Pad...................................................................................................... 65
Eccentric Hub Assembly............................................................................... 66
CONTENTS

Page ix
First Reduction Shaft Assembly .................................................................. 66
Handlebar (4400 PT/CL, 4200 PT) ............................................................... 66
Upper Handles (4600 PT/CL)........................................................................ 67
Side Handrails (4600 PT/CL)........................................................................67
Alternator...................................................................................................... 68
GROUNDING INSTRUCTIONS......................................................................... 69
FCC COMPLIANCE............................................................................................. 70
APPENDICES
Canadian Doc Class B Compliance............................................................. 70
Important Phone Numbers...........................................................................71
Battery Recycling Centers ...........................................................................72
Figures 10-27................................................................................................ 74
LIST OF TABLES
Table 1. Dimensions and Specifications for the
StairMaster®FreeClimber® Exercise Systems .................................. 5
Table 2. Fitness Rating Norms (VO2max)........................................................ 29
Table 3. Recommended Preventive Maintenance Schedule ....................43
LIST OF ILLUSTRATIONS
Figure 1: Major Parts - 4600 PT/CL ................................................................. 3
Figure 2: Major Parts - 4200 PT and 4400 PT/CL ......................................... 4
Figure 3: Level Adjusting End Caps............................................................... 6
Figure 4: DC Power Connector....................................................................... 7
Figure 5: Correct Exercise Postion...............................................................12
Figure 6: Transmitter Belt............................................................................. 16
Figure 7: FreeClimber 4400/4600 PT/CL Systems Console.......................18
Figure 8: StairMaster Fitness Protocol........................................................28
Figure 9: 4200 PT Console Diagram............................................................ 35
Figure 10: Grounding System ......................................................................69
Figure 11: Parts Needing Periodic Maintenance .......................................74
CONTENTS

Page x
Figure 12: Final Assembly - Left, 4600 PT ................................................... 75
Figure 13: Final Assembly - Right, 4600 PT.................................................76
Figure 14: Final Assembly - Left, 4600 CL ................................................... 77
Figure 15: Final Assembly - Right, 4600 CL.................................................78
Figure 16: Covers - 4600 PT/CL................................................................... 79
Figure 17: Pedal Arm Assembly & First Reduction Shaft Assembly
(4600/4400 PT/CL, 4200 PT) ........................................................ 80
Figure 18: Drive Shaft Assembly & Eccentric Hub Assembly
(4600/4400 PT/CL, 4200 PT) ........................................................ 81
Figure 19: Final Assembly - Left, 4400/4200 PT......................................... 82
Figure 20: Final Assembly - Right, 4400/4200 PT....................................... 83
Figure 21: Final Assembly - Left, 4400 CL ................................................... 84
Figure 22: Final Assembly - Right, 4400 CL.................................................85
Figure 23: Covers - 4400 PT/CL, 4200 PT ...................................................86
Figure 24: Cover Removal............................................................................ 87
Figure 25: Cover Fasteners .......................................................................... 88
Figure 26: Drive Chain Tensioning.............................................................. 89
Figure 27: Belt Tension................................................................................ 90
CONTENTS

Page 1
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:
IMPORTANT SAFETY INSTRUCTIONS
This symbol appearing throughout this manual means
Attention! Be Alert! Your safety is involved.
The following definitions apply to the words “Danger” and “Warning”
found throughout this manual:
DANGER - Used to call attention to IMMEDIATE hazards which, if not
avoided, will result in immediate, serious personal injury or loss of life.
WARNING - Used to call attention to POTENTIAL hazards that could
result in personal injury or loss of life.
READ ALL INSTRUCTIONS BEFORE USING THE MACHINE.
To reduce the risk of electrical shock, always unplug
the external power supply from the AC wall outlet
before cleaning, maintaining, or repairing.
To reduce the risk of burns, electric shock, or injury
to persons:
1. The external power supply should always be unplugged from the AC wall
outlet before removing or installing parts. Never make adjustments or
repairs while an exercise program is in progress.
2. Close supervision is necessary whenever the machine is used by or near
children, invalids, or disabled persons.
3. Keep your hands away from all moving parts and keep your feet on the
pedals while exercising. Do not operate the machine with the side covers
removed.
SAFETY GUIDELINES
!
DANGER
!
WARNING
!

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.
5. Do not use the external power supply if it has a damaged cord or plug, or if
it is not working properly, if it has been dropped or damaged, or dropped
into water. Contact our Customer Service Department at 1-800-331-
3578 to arrange for the return of damaged parts.
6. Connect the external power supply to a properly grounded AC wall
outlet; refer to the “Grounding Instructions” section. Keep all cords
away from heated surfaces.
7. To disconnect the external power supply, remove the plug from the AC
wall outlet.
8. Never drop or insert any object into any opening on the machine.
9. Do not operate where aerosol (spray) products are being used.
10. Always wear insulated gloves when handling batteries.
11. Do not crush, incinerate, or dismantle the battery. The electrolyte contains
sulfuric acid which can cause serious damage to eyes and skin. Should
this occur, flush profusely with water and seek medical attention.
12. Do not use the machine outdoors.
The safety level given by the design of this equipment can only be
maintained when the equipment is regularly examined for damage and wear.
Inoperable components shall be replaced immediately or the equipment shall
be put out of use until it is repaired. Failure to follow all guidelines may com-
promise the effectiveness of the exercise experience, expose yourself (and
possibly others) to injury, and reduce the longevity of the machine. Follow all
training instructions listed in the manual and/or on the machine. Physical injury
may result from incorrect or excessive training.
SAVE THESE INSTRUCTIONS
SAFETY GUIDELINES

Page 3
Before leaving the manufacturing facility in Tulsa, Oklahoma, your
StairMaster®FreeClimber®exercise system was thoroughly inspected and
tested to ensure proper operation. The major parts of the machine are shown
in Figures 1 and 2.
Figure 1: Major Parts - 4600 PT/CL
INTRODUCTION

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 Table 1.
Table 1. Dimensions and Specifications for the
StairMaster®FreeClimber®Exercise Systems
Physical Dimensions:
Length 44 inches (104 cm)
Width at Front Leg (4400 PT/CL, 4200 PT) 22 inches (56 cm)
Width at Front Leg (4600 PT/CL) 32 inches (82 cm)
Height 69 inches (176 cm)
Weight
4400 PT/CL, 4200 PT 126 pounds (55 kg)
4600 PT/CL 155 pounds (70 kg)
Power Supply Specifications:
4600/4400/4200 PT (U.S., Canada, Japan) 120 VAC, 50/60 Hz, 2.5 Amp
4600/4400/4200 PT (International) 230 VAC, 50/60 Hz, 2.5 Amp
Battery Charger Specifications:
4600/4400 CL (U.S., Canada, Japan) 120 VAC, 50/60 Hz, 1 Amp
4600/4400 CL (International) 230 VAC, 50/60 Hz, 1 Amp
Internal Battery
6 volt, 1 Ah Lead-Acid battery
INTRODUCTION

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.
2. Make sure the machine is level before you use it for the first time. The
four rubber end caps (see Figure 3) are designed to compensate for
uneven floors. Each face of the caps is a different thickness. Twist the
caps to stabilize the machine.
Figure 3: Level Adjusting End Caps
3. Open the box you removed from the pedals. The box contains either
an external power supply (4600/4400/4200 PT only) or a wall-pack
battery charger (4600/4400 CL only). The battery charger is only
used torecharge a low battery.
INSTALLATION INSTRUCTIONS

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. To reduce
the hazard of electrical shock, place the power supply in a location
away from the machine and away from exposure to perspiration. You
should not place your power supply on a carpet because it may over
heat.
INSTALLATION INSTRUCTIONS

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-
ing power supply from StairMaster®Health & Fitness Products, Inc.
before proceeding any further.
7. Connect the AC power cord to the AC wall outlet. Refer to the
“Grounding Instructions” section if the AC wall outlet does not
accept athree-prong plug.
8. Watch the console. The 4600/4400 PT should display a software
revision code and then show “SELECT WORKOUT.” The 4200 PT
console should run through a self test and then display a moving line
in the upper LCD window. If the console does not, unplug the power
supply and then plug it back in. If the console still does not power up
correctly, contact our Customer Service Department. Refer to the
Appendix for the appropriate phone number.
9. If you have a 4600/4400 CL, step on the pedals to check for proper
operation. Once you step on the pedals, the console should display a
software revision code and then show “SELECT WORKOUT.” If it
does not, connect the battery charger to the connector on the lower
left side. If the console still does not power up contact our Customer
Service Department. Refer to the Appendix for the appropriate phone
number.
10. The display “SELECT WORKOUT” tells you the machine is ready to
use. The 4600/4400 PT/CL console displays this message and the
4200 PT displays a moving line in the upper LCD window when the
console is ready to use.
INSTALLATION INSTRUCTIONS
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO
PREVENTSEVERE DAMAGE TO THEMACHINE, USE ONLYTHE POWER SUPPLY
APPROVED FORUSEWITHTHIS EQUIPMENT. INADDITION,
YOURMACHINEMUSTBEPROPERLYGROUNDED.
!WARNING

Page 9
GENERAL GUIDELINES FOR SAFE OPERATION
1. Obtain a complete physical examination from your medical doctor and
enlist a health/fitness professional’s aid in developing an exercise
program suitable for your current health status.
2. When working out for the first time, use the MANUAL exercise
program at the lower speeds until you feel comfortable and capable
of faster speeds.
3. The speed and duration of your exercise program should always be
subject to how you feel. Never permit peer pressure to override your
personal judgment while exercising.
4. Overweight or severely deconditioned individuals should be particu-
larly cautious when using the machine for the first time. Even though
such individuals may not have histories of serious physical problems,
they may perceive the exercise to be far less intense than it really is,
resulting in the possibility of overexertion or injury.
5. Although all equipment manufactured by StairMaster®Health &
Fitness Products, Inc. has been thoroughly inspected by the manufac-
turing facility prior to shipment, proper installation and regular mainte-
nance are required to ensure safety. Maintenance is the sole respon-
sibility of the owner.
BASIC OPERATING INSTRUCTIONS
!WARNING
THESEGUIDELINES ARE DIRECTED TOYOU,ASTHEOWNER OF THE MACHINE.
YOU SHOULDINSISTTHATALLUSERSFOLLOWTHESAMEGUIDELINES.
YOUSHOULDMAKETHISMANUALAVAILABLETOALLUSERS.

Page 10
YOUR FIRST WORKOUT ON THE STAIRMASTER®FREECLIMBER®
EXERCISE SYSTEM
1. Warm up with light calisthenics and easy stretching exercises for at
least five minutes before beginning your exercise program.
2. Hold onto the handlebars and step up onto the pedals. Stand up
straight. The pedals will sink slowly toward the floor.
3. Select the MANUAL exercise program so you can control the pace of
your first workout and get used to the exercise motion. Press
[MANUAL] and then press [ENTER]. The console will return to
the start screen if you do not press [ENTER] within 60 seconds.
4. The console will prompt you to enter your body weight. Enter your
weight in pounds (or kilograms if the console is set up for metric
units). Correct entry errors by pressing [CLEAR] before you press
[ENTER].
5. The console will prompt you to enter your intensity level. Enter your
desired intensity level. Correct entry errors by pressing [CLEAR] before
you press [ENTER].
6. The console will prompt you to enter the workout time in one minute
increments between 5 and 99 minutes. Press [1], [0], [ENTER] to
exercise for ten minutes. If you do not start exercising within 60
seconds, the console will return to the start screen.
Begin Exercising
7. Take deep, comfortable steps. Do not let the pedals touch the floor or
contact the upper stop. When you begin to exercise, the MANUAL
BASIC OPERATING INSTRUCTIONS
!WARNING
IFAT ANYTIMEDURINGYOUR WORKOUTYOUFEEL CHESTPAIN,
EXPERIENCE SEVERE MUSCULAR DISCOMFORT, FEEL FAINT, OR ARE SHORT OF
BREATH, STOP EXERCISING IMMEDIATELY. IF THE CONDITION PERSISTS, YOU
SHOULDCONSULTYOURMEDICALDOCTORIMMEDIATELY.