Stairmaster FreeClimber 4600 PT User manual

FreeClimber®Systems
Owner’s Manual

© 1997 StairMaster Sports/Medical Products, Inc., StairMaster and FreeClimber are
registered trademarks or trademarks of StairMaster Sports/Medical Products, Inc. in the United States
and /or other countries. All other trademarks are trademarks of their respective companies.
P/N 22569-E
Printed in the United States.
©1997 StairMaster® Sports/Medical Products, Inc.
All rights reserved.
Corporate Headquarters
12421 Willows Road N.E., Suite 100
Kirkland, WA 98034
[phone]
[phone]
Fax [phone]
www.stairmaster.com
Page iii

Page iv
10 REASONS WHY MORE HEALTH AND FITNESS
FACILITIES CHOOSE STAIRMASTER®EQUIPMENT
OUTSTANDING QUALITY
Equipment you can depend upon, week after week, for heavy commercial use –
instead of a sign that says "out of order."
EXCEPTIONAL PERFORMANCE
Generates exceptional customer satisfaction – allowing you to retain existing
club members and attract new ones.
IMMEDIATE CUSTOMER RECOGNITION
An excellent first impression is critical to attracting new club members to your
facility. The StairMaster name on your equipment reinforces your club's reputa-
tion for quality and effectiveness.
NATIONAL SALES SUPPORT
StairMaster is one of the few organizations that maintains its own fully staffed
national sales organization. These individuals will bend over backwards to make
sure you are satisfied.
FACTORY-TRAINED SERVICE NETWORK
The StairMaster service staff is on call to quickly address any product
concerns. Service is just a toll-free call away.
FACTORY DIRECT PRICES
No warehousing fee. No retail markup. StairMaster sells directly to you for the
bestpricesavailable.
AFFORDABLE LEASING PROGRAM
We help you make the most of your money, with several types of leasing
programsavailable.
FACILITY PLANNING
Cordless units. Space-efficient designs. Exciting facility layout plans. Our staff
works closely with you to maximize the equipment layout of your club or fitness
area.
PRE-ASSEMBLED DELIVERY
No set-up, no hassle.
MARKETING SUPPORT
Lots of sizzle – with StairMaster product catalogs, posters, promotional kits, and
seasonalpromotions.

Page v
A FULL LINE OF EXCEPTIONAL PRODUCTS
STAIRCLIMBERS
The Best in the Industry
Our popular FreeClimber®stairclimber
line now offers you 5 different models
to choose from. These models include
the new fully featured FreeClimber
4600 PT and the cordless FreeClimber
4600 CL, along with the FreeClimber
4400 PT and the cordless FreeClimber
4400 CL with Polar®Heart Rate
Monitor, and the cost-efficient
FreeClimber 4200 PT –all designed
especially for health clubs.
Other StairMaster®stairclimbers
include the Stepmill® 7000 PT –for the
mostchallengingstairclimbing
workout –as well as the legendary
StairMaster 4000 PT®.
ELLIPTICAL STRIDING SYSTEMS
The New StairMaster FreeRunner
Introducing the StairMaster
FreeRunner™5400 ESS –a revolution-
ary new design that allows you
to vary your stride length from 10'’to
40." Not only does this unique VSL
feature accommodate all users, it also
provides enhanced lower-body
conditioning –with greater
involvement of the glutes,
quadriceps, and hamstrings.
For total-body conditioning, club
members will love the fact they can
use the handles on the StairMaster
FreeRunner 5400 for an effective
upper-body workout. These handles
can also be easily disengaged to rest
on the side of the machine.

Page vi
A FULL LINE OF EXCEPTIONAL PRODUCTS
TREADMILLS
The Highest Quality
In response to many requests we
received from our customers for a high
quality treadmill, StairMaster®has
selected the Quinton® treadmill as a
new addition to our product line –with
four different models to choose from –
the ClubTrack® 510, the ClubTrack® 510
Plus, the ClubTrack® 612 and the
ClubTrack® 612 Plus. Only Quinton
could match the StairMaster reputa-
tion for maximum performance,
durability, and product safety.
STRATUS EXERCISE BIKES
New Models & Prices
At last –a cordless line of variable
resistance exercise bikes that not only
provide the exciting workout programs
that StairMaster is famous for, but are
designedwithsuchuncompromising
attention to every biomechanical
detail, they offer you extraordinary
safety and comfort.
Introducing Stratus exercise bikes –a
new cordless variable resistance line
from StairMaster –that are available
with either an upright or recumbent
seat. Just like StairMaster's legend-
ary stairclimbers, Stratus exercise
bikes are very different from other
models –simply because they feel so
good to use.

Page vii
A FULL LINE OF EXCEPTIONAL PRODUCTS
CROSSROBICS®
The Ultimate Exercise Machines
The StairMaster®Crossrobics products
are innovative machines that combine
aerobic exercise with a weight stack
for strength conditioning. Available
only from StairMaster, the Crossrobics
machines provide the ultimate
workout.
StairMaster offers you two
Crossrobics machines –the
Crossrobics 1650 LE and the
Crossrobics 2650 UE Kayak. Both
products feature an easy-to-
operate, first-time user option as
well as a quick-start feature.
STAIRMASTER STRENGTH
SYSTEMS
Feel the Difference
Club members will feel the difference
the first time they use StairMaster®
strength equipment –designed to
work the way your body works.
Consisting of the Gravitron®2000 AT
and the new Arcuate®and Linear™
lines, StairMaster offers you 17
different strength training products to
choose from. To ensure the highest
quality, all StairMaster strength
equipment is now manufactured at our
own factory in Tulsa, Oklahoma.

Page viii
WARRANTY
ThisistocertifythattheStairMaster®FreeClimber®exercisesystemiswarranted
byStairMasterSports/Medical Products, Inc. to befreeofalldefects in materials
andworkmanship. This warranty doesnotapply to any defectcausedby negligence,
misuse,accident,alteration,impropermaintenance,oran“actofGod”.Thiswarranty
isnon-transferablefromtheoriginalowner.
If,within three years fromthedate of purchase,anypartof the StairMaster
FreeClimberexercisesystemshouldfailto operate properly (except any accessories orthe
batteryon the 4600CL and the4400 CL), contactourCustomer Service Departmentto
reporttheproblem When calling,pleasebeprepared to provide thecustomerservice
representativewiththefollowinginformation:
•Yourname,customer number,shippingaddress, and telephonenumber
•Themodel and serial number ofthe inoperable machine
•Thedate(s) of purchaseforthe inoperable machine(s)
•Yourbillingaddress
Thisinformation will ensure thatyouare the onlyoneordering parts underyour
warrantyprotection.If warranty replacement partsare shippedtoyou,youmay be
requiredtoreturn the inoperable part.To facilitatethisprocess,the following policy has
beenestablished:
•Pleasecallour Customer Service Departmenttoreceivea return
goodsauthorizationpriortoshipment.
•StairMasterSports/MedicalProducts, Inc. will incurallfreight
chargesfor warranty parts orderedfor a machine thatisless than 45
daysold. The partswill be shipped toyou via anovernightcourier.*
•You areresponsiblefor freight chargesonwarranty parts for
machinesthat are morethan 45 daysold. Youwill not beresponsible
forthereturn shipment of theinoperableparts.
•Someinoperablewarranty parts mustbepromptlyreturned to our
CustomerServiceDepartment. Wewill pay the shippingcost forthe
inoperablewarrantyparts. Detailed instructions areincludedwith
eachwarranty replacement part.
StairMasterSports/MedicalProducts, Inc. neither makes, assumes nor
authorizesany representative or otherpersonto make orassumefor us, any other
warrantywhatsoever,whetherexpressed or implied, in connection with the sale,service,
orshipment of our products.Wereserve the righttomake changes andimprovementsin
ourproductswithoutincurring any obligation to similarly alter products previously
purchased.In order to maintainyourproduct warranty andtoensurethe safe andefficient
operationofyour machine, only authorizedreplacementpartscan be used. Thiswarranty
isvoidif parts other thanthoseprovidedby StairMaster Sports/Medical Products,Inc. are
used.
*Note: Aerosol products cannotbetransported via air.

Page ix
PREFACE
Regular use of the Stairmaster®FreeClimber®exercise system is a safe and
effective way to develop aerobic fitness while conditioning the major muscles
of the lower body. In order to get the best results, and to keep your machine in
peak operating condition, you should carefully read and follow the guidelines
presented in this manual.
WHAT IS IN THIS MANUAL?
The first 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 is in
the ATTRACT mode. Press [MANUAL] to start the MANUAL exercise program.
WHAT IS THE STAIRMASTER FREECLIMBER EXERCISE SYSTEM?
The StairMaster FreeClimber exercise systems are vertical climbing machines
with an independent step action. The independent step action, combined with
the patented pedal geometry featured on all StairMaster steppers, provides an
aerobic workout equivalent to uphill running or climbing stairs, but without the
high-impact pounding to the joints and muscles.
There are five FreeClimber models: the 4600 PT (Personal Trainer),
the 4600 CL (Cord Less), the 4400 PT, the 4400 CL, and the 4200 PT. All
FreeClimbers feature the Quiet Drive transmission. The 4600 PT and the
4600 CL have an adjustable tilting, full-featured console with a Light Emitting
Diode (LED) display. The 4400 PT and the 4400 CL have an upright, rail-less
design. The 4600 PT and the 4400 PT use an external power supply that is
plugged into an AC wall outlet. The 4600 CL and the 4400 CL use power gener-
ated during a workout to run the electronics. The 4600 PT and 4600 CL have
contact heart rate and Polar®heart rate monitoring. The 4400 PT and the 4400 CL
feature Polar®heart rate monitoring. The 4200 PT uses an external power supply
to run a Liquid Crystal Display (LCD) console. This LCD console has less feedback
and fewer workout programs than the LED console on the 4600 PT/CL and the
4400 PT/CL.

Page x
CONTENTS
SAFFETY GUIDELINES ........................................................................................ 1
INTRODUCTION ................................................................................................... 3
INSTALLATION INSTRUCTIONS........................................................................ 6
BASIC OPERATING INSTRUCTIONS ................................................................ 9
General Guidelines for Safe Operation........................................................... 9
Your First Workout......................................................................................... 10
The ATTRACT Mode .............................................................................. 10
Basic Instructions for First-Time Users ................................................. 10
4600/4400 PT/CL Console Set-Up......................................................... 10
4200 PT Console Set-Up........................................................................ 11
BeginExercising .................................................................................... 11
CONTACT HEART RATE (4600 PT/CL ONLY)................................................... 13
POLAR®HEART RATE (4600/4400 PT/CL ONLY)............................................. 14
FREECLIMBER 4600/4400 PT/CL CONSOLE.................................................... 15
Text Bar.......................................................................................................... 16
Display........................................................................................................... 16
Function Keypad ............................................................................................ 16
Entertainment Keypad (4600 PT/CL) ............................................................. 18
Exercise Program Keypad.............................................................................. 18
The Quick Start Option .................................................................................. 19
The Fit Test .................................................................................................... 19
Preset Exercise Programs.............................................................................. 21
4600 PT/CL: ........................................................................................... 21
4400 PT/CL: ........................................................................................... 21
The Jackpot Option ....................................................................................... 22
Turning the Jackpot Option On and Off................................................. 23
Custom Exercise Programs............................................................................ 23
Programming Your Workout .................................................................. 23
Using a Custom Program....................................................................... 24
Custom Scrolling Message ........................................................................... 24
Editing The Scrolling Message ..................................................................... 25
Changing the Console Units and Language .................................................. 26
Console Codes............................................................................................... 26

Page xi
CONTENTS
FREECLIMBER 4200 PT CONSOLE................................................................... 28
Top Window .................................................................................................. 28
Workout Setup ...................................................................................... 28
Timer...................................................................................................... 30
Bottom Window ............................................................................................ 30
Keypad................................................................................................... 31
Quick Start Option ......................................................................................... 31
MAINTENANCE INSTRUCTIONS ................................................................... 32
Helpful Hints.................................................................................................. 32
Tool List ......................................................................................................... 32
Maintenance Records ................................................................................... 32
InitialService................................................................................................. 33
Preventive Maintenance ............................................................................... 33
Cleaning................................................................................................. 33
Inspecting .............................................................................................. 33
Lubrication............................................................................................. 34
Battery Charge....................................................................................... 35
Battery Disposal .................................................................................... 35
TROUBLESHOOTING ......................................................................................... 37
General Troubleshooting Guidelines ............................................................. 37
Electrical Troubleshooting............................................................................. 37
4600/4400 PT:........................................................................................ 37
Alternator Test ................................................................................ 38
Diode Test ....................................................................................... 39
Resistor Test ................................................................................... 39
4600/4400 CL: ....................................................................................... 39
Battery Test..................................................................................... 39
Alternator Test ................................................................................ 40
Resistor Test ................................................................................... 40
4600/4400 PT/CL Console Diagnostics................................................. 41
Display Test..................................................................................... 41
Speaker Test ................................................................................... 41
Keypad Test..................................................................................... 41
Speed Test ...................................................................................... 42
Software Revision Level Test ......................................................... 42
Contact Heart Rate Test.................................................................. 43
Polar® Heart Rate Test .................................................................... 43

Page xii
Mechanical Troubleshooting......................................................................... 45
PARTS REMOVAL AND REPLACEMENT ........................................................ 48
Covers............................................................................................................ 48
Mid Cover .............................................................................................. 48
Top Cover ............................................................................................... 48
Shield (4600 PT/CL ) .............................................................................. 49
Bottom Cover......................................................................................... 49
Console.......................................................................................................... 50
Console Adjustment (4600 PT/CL)................................................................. 50
Poly-V and HTD Belt ...................................................................................... 50
Step Chain Retainer ...................................................................................... 51
Pedal Arm Return Spring............................................................................... 51
Step Chain ..................................................................................................... 52
SpringPulley.................................................................................................. 53
Drive Chain .................................................................................................... 53
Drive Shaft Assembly.................................................................................... 54
Pedal.............................................................................................................. 56
LevelingArm.................................................................................................. 56
Pedal Arm ...................................................................................................... 57
Pedal Pad....................................................................................................... 57
Eccentric Hub Assembly................................................................................ 58
First Reduction Shaft Assembly .................................................................... 58
Handlebar (4400 PT/CL ,4200 PT).................................................................. 58
Upper Handles (4600 PT/CL) ......................................................................... 59
Side Handrails (4600 PT/CL).......................................................................... 59
Alternator ...................................................................................................... 60
GROUNDING INSTRUCTIONS ......................................................................... 61
FCC COMPLIANCE............................................................................................. 62
APPENDICES
Canadian Doc Class B Compliance ............................................................... 62
Important Phone Numbers ............................................................................ 63
Battery Recycling Centers ............................................................................. 64
Figures 10-30................................................................................................. 66
CONTENTS

Page xiii
LIST OF TABLES
Table 1. Dimensions and Specifications for the
StairMaster®FreeClimber® Exercise Systems .................................. 5
Table 2. Fitness Rating Norms (METs)........................................................... 20
Table 3: Character Codes for the Scrolling Message ................................... 25
Table 4. Console Codes ................................................................................. 27
Table 5. Recommended Preventive Maintenance Schedule......................... 36
LIST OF ILLUSTRATIONS
Figure 1: Major Parts - 4600 PT/CL ................................................................. 3
Figure 2: Major Parts - 4400 PT/CL ................................................................. 4
Figure 3: Level Adjusting End Caps................................................................. 6
Figure 4: DC Power Connector ........................................................................ 7
Figure 5: Correct Exercise Posture ................................................................ 12
Figure 6: 4600 PT/CL Console Diagram......................................................... 15
Figure 7: 4400 PT/CL Console Diagram......................................................... 15
Figure 8: 4200 PT Console Diagram .............................................................. 28
Figure 9: Grounding System .......................................................................... 61
Figure 10: Parts Needing Periodic Maintenance .......................................... 66
Figure 11: Final Assembly - Left, 4600 PT ..................................................... 67
Figure 12: Final Assembly - Right,4600 PT.................................................... 68
Figure 13: Final Assembly - Left, 4600 CL ..................................................... 69
Figure 14: Final Assembly - Right, 4600 CL................................................... 70
Figure 15: Covers - 4600 PT/CL ..................................................................... 71
Figure 16: Pedal Arm Assembly & First Reduction Shaft Assembly
(4600/4400 PT/CL, 4200 PT) .......................................................... 72
Figure 17: Drive Shaft Assembly & Eccentric Hub Assembly
(4600/4400 PT/CL, 4200 PT) .......................................................... 73
Figure 18: Final Assembly - Left, 4400/4200 PT ........................................... 74
Figure 19: Final Assembly - Right, 4400/4200 PT ......................................... 75
Figure 20: Final Assembly - Left, 4400 CL.................................................... 76
Figure 21: Final Assembly - Right, 4400 CL.................................................. 77
Figure 22: Covers - 4400 PT/CL, 4200 PT ...................................................... 78
Figure 23: Cover Removal.............................................................................. 79
Figure 24: Cover fasteners ............................................................................ 80
Figure 25: Drive Chain tensioning ................................................................ 81
Figure 26: Belt Tension................................................................................. 82
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,ordisabledpersons.
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®Sports/Medical Products, Inc.
5. Do not use the external power supply if it has a damaged cord or plug, if it
is not working properly, if it has been dropped or damaged, or dropped into
water. Contact our Customer Service Department to arrange for the return of
damaged parts. Refer to the Appendix for the appropriate phone number.
6. Connect the 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
walloutlet.
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
medicalattention.
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 compromise
the effectiveness of the exercise experience, expose yourself (and possibly
others) to injury, and reduce the longevity of the machine. Follow all training
instructions listed in the manual and/or on the machine. Physical injury may
result from incorrect or excessive training.
SAVE THESE INSTRUCTIONS
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 - 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 41 inches (104 cm)
Width at Front Leg (4400 PT/CL, 4200 PT) 22 inches (56cm)
Width at Front Leg (4600 PT/CL) 32 inches (82cm)
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 to
recharge 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 matching
power supply from StairMaster®Sports/Medical 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 a three-prong plug.
8. Watch the console. The 4600/4400 PT should scroll a copyright
message and then display a simulated EKG signal. The 4200 PT console
should run through a self test and then display a moving line in the
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 produce an
audible sound and display a simulated EKG in the display area. If it does
not, connect the battery charger to the connector on the lower right
side. If the console still does not power up contact our Customer Service
Department. Refer to the Appendix for the appropriate phone number.
10. The ATTRACT mode tells you the machine is ready to use. The 4600/
4400 PT/CL console displays a simulated EKG signal and the 4200 PT
displays a moving line in the upper LCD window when the console is in
the ATTRACT mode.
INSTALLATION INSTRUCTIONS
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO
PREVENT SEVERE DAMAGE TO THE MACHINE, USE ONLY THE POWER SUPPLY AP-
PROVEDFOR USE WITHTHIS EQUIPMENT. IN ADDITION,
YOUR MACHINE MUST BE PROPERLY GROUNDED.
!WARNING