Stairmaster FreeClimber User manual

FreeClimber" Systems
Owner's Manual

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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
Stall
PIN 22569-E
<0 1997 StairMaster Sports/Medical Products . Inc .• Sta i rMaster and FreeClimber are
reg i stered trademarks or trademarks of StairMaster Sports/Medical Products . Inc .in the United States
and lor other countries. All other trademarks are trademarks of their respective companies .
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10 REASONS WHY MORE HEALTH AND FITNESS
FACILITIES CHOOSE STAIRMASTER~ EQUIPMENT
OUTSTANDING QUALITY
Equ i pment 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 i mpression 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
Stai r Master is one of the few organizat i ons that ma i nta i ns i ts own f ully staffed
national sales organization. These individuals wil l 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
best prices ava i lable .
AFFORDABLE LEASING PROGRAM
We help you make the most of your money, with several types of leasing
programs available .
FACILITY PLANNING
Cordless units. Space-efficient designs. Exciting facility layout plans . Our staff
works closely with you to maxim i ze the equipment layout of your club or fitness
area .
PRE-ASSEMBLED DELIVERY
No set-up, no hassle.
MARKETING SUPPORT
Lots of sizzle - with Sta i rMaster product catalogs , posters , promot i onal kits , and
seasonal promotions.
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FULL LINE OF EXCEPTIONAL PRODUCTS
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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 wi th the FreeCl i mber
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
i nclude the Stepmill ~ 7000 PT - for the
most challenging stairclimb i ng
workout - as well as the legendary
Stai r Master 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 un i que VSL
feature accommodate all users, it also
provides enhanced lower-body
condit i oning - wi th greater
involvement of the glutes,
quadriceps , and hamstr i ngs .
For total-body condition i ng, 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.
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FULL LINE OF EXCEPTIONAL PRODUCTS
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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 Club Track ~ 612 and the
ClubTrack ~ 612 Plus. Only Quinton
could match the StairMaster reputa-
tion for maximum performance,
durability, and product safety .
Page vi
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
designed with such uncompromising
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.

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FULL LINE OF EXCEPTIONAL PRODUCTS
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CROSSROBICS~
The Ultimate Exercise Machines
The StairMaster ~ Crossrobics products
are i nnovative machines that combine
aerobic exercise with a weight stack
for strength conditioning. Available
only from StairMaster, the Crossrobics
machines provide the ultimate
workout.
Stai r Master 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.
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WARRANTY
This is to certify that the StairMaster ® FreeClimber® exercise system is warranted
by St airMaster Sports/Medical Products , Inc . to be free of all defects in materials
and workmanship . This warranty does not apply to any defect caused by negligence,
misuse , accident, alteration , improper maintenance , or an " act of God ". This warranty
is non - transferable from the original owner .
If,
within three years from the date of purchase , any part of the StairMaster
FreeClimber exercise system should fail to operate properly (except any accessories or the
battery on the 4600 Cl and the 4400 Cl) , contact our Customer Service Department to
report the problem When calling , please be prepared to provide the customer service
representative with the following information :
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Your name, customer number , shipping address , and telephone number
• The model and serial number of the inoperable machine
• The date(s) of purchase for the inoperable machine(s)
• Your bi II ing address
This information will ensure that you are the only one ordering parts under your
warranty protection. If warranty replacement parts are shipped to you , you may be
requ i red to return the inoperable part. To facilitate this process, the following policy has
been established:
Please call our Customer Service Department to receive a return
goods authorization prior to shipment.
StairMaster Sports/Medical 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
machines that are more than 45 days old. You will not be responsible
for the return shipment of the inoperable parts .
Some inoperable warranty parts must be promptly returned to our
Customer Service Department. We will pay the shipping cost for the
inoperable warranty parts. Detailed instructions are included with
each warranty replacement part .
StairMaster Sports/Medical Products , Inc. neither makes , assumes nor
authorizes any representat i ve or other person to make or assume for us , any other
warranty whatsoever , whether expressed or implied , in connection with the sale, service ,
or sh i pment 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 Sports/Medical Products , Inc . are
used .
*
Note : Aerosol products cannot be transported via air .
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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 ICL and the
4400 PT/CL.
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CONTENTS
SAFFETV GUIDELINES 1
INTRODUCTION 3
INSTALLATION INSTRUCTIONS 6
BASIC OPERATING INSTRUCTIONS 9
Genera lG ui de li nes for Safe Ope ra ti on 9
You r First Wo r kout 10
The ATIRACT Mode 10
Bas ic Instruct i ons for Fi rst-T i me Users 10
4600/4400 PT I CL Conso le Set - Up 10
4200 PT Console Set-Up 11
Begin Exerc isi ng 11
CONTACT HEART RATE (4600 PTICL ONLY) 13
POLAR- HEART RATE (4600/4400 PTICL ONLY) 14
FREECLIMBER 4600/4400 PTICL CONSOLE 15
Text Bar : 16
Disp l ay 16
Funct i on Keypad 16
Enterta i nmen t Keypad ( 4600 PT ICL )18
Exerc i se Program Keypad 18
The Quick Start Opt i on 19
The Fit Test 19
Preset Exerc i se Programs 21
4600 PT ICL : 21
4400 PT ICL : 21
The Jackpot Option 22
Turning the Jackpot Option On and Off 23
Custom Exerc i se Programs 23
Programming Your Workout 23
Us i ng a Custom Program 24
Custom Scro lli ng Message 24
Ed iti ng The Scroll i ng Message 25
Chang i ng the Console Un i ts and Language 26
Console Codes 26
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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
Initial Service 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
Di splay Test 41
Speaker Test 41
Keypad Test 41
Speed Test 42
Software Revision Level Test 42
Contact Heart Rate Test.. 43
Polar l!!l Heart Rate Test 43
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CONTENTS
Mechan i cal Troubleshooting 45
PARTS REMOVAL AND REPLACEMENT 48
Covers 48
Mid Cover 48
Top Cover 48
Sh i eld (4600 PT /CL) 49
Bottom Cover 49
Console ~ 50
Console Adjustment (4600 PT /CL) 50
Po l y-V and HTD Belt " , , 50
Step Chain Reta i ner 51
Peda I Arm Return Spri ng 51
Step Chain 52
Spring Pulley 53
Drive Chain 53
Drive Shaft Assembly 54
Pedal 56
Leveling Arm 56
Pedal Arm 57
Pedal Pad 57
Eccentr ic Hub Assembly 58
Fi rst Reduct i on Shaft Assembly 58
Handlebar (4400 PT /CL ,4200 pn 58
Upper Handles (4600 PT /CL) 59
Side Hand r ails (4600 PT /CL) 59
Al ternator 60
GROUNDING INSTRUCTIONS 61
FCC COMPLIANCE 62
APPENDICES
Canad i an Doc Class B Compliance 62
Important Phone Numbers 63
Battery Recycling Centers 64
Figures 10-30 66
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CONTENTS
LIST OF TABLES
Table 1. Dimens i ons and Specif i cat i ons for the
Sta i rMaster l!l) FreeClimber l!l) Exerc i se Systems 5
Table 2. Fitness Rating Norms (METs ) 20
Table 3: Character Codes for the Scro lli ng Message 25
Table 4. Conso le Codes 27
Table 5. Recommended Preventive Maintenance Schedule 36
LIST OF ILLUSTRATIONS
Figure 1: Major Parts - 4600 PT ICL 3
Fi
gure 2: Major Parts - 4400 PT ICL 4
Fi
gure 3: Level Adjusting End Caps 6
Figure 4: DC Power Connector 7
Figure 5: Correct Exercise Posture 12
Figure 6: 4600 PT ICL Console Diagram 15
Figure 7: 4400 PT ICL Console Diagram 15
Figure 8: 4200 PT Console Diagram 28
Figure 9: Grounding System 61
Fi gure 10 : Parts Needing Periodic Ma i ntenance 66
Fi gure 11 :Fi na l Assembly - Left , 4600 PT 67
Fi gure 12 :Fi na l Assembly - Right,4600 PT 68
Figure 13 :Fi na l Assembly - Left, 4600 CL 69
Figure 14 :Fi nal Assembly - Right, 4600 CL 70
Figure 15 : Covers - 4600 PT ICL 71
Figure 16 : Pedal Arm Assembly &Fi rst Reduct i on Shaft Assembly
(4600/4400 PT ICL, 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 ICL, 4200 PT 78
Figure 23 : Cover Removal 79
Figure 24 : Cover fasteners 80
Figure 25 : Drive Chain tensioning 81
Figure 26: Belt Tension 82
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SAFETY GUIDELINES
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOUOW THESE BASIC PRECAUTIONS:
IMPORTANT SAFETY INSTRUCTIONS
This symbol appearing throughout this manual means
Attention! Be Alert! Your safety is involved.
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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 .
.&. DANGER To reduce the risk of electrical shock, always unplug
the external power supply from the AC wall outlet
before cleaning, maintaining, or repairing .
.&. WARNING 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.
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SAFETY GUIDELINES
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
wa II 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 ac id 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 equ i pment can only be
maintained when the equipment is regularly exam i ned 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
othe r s) 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
resu lt from incorrect or excessive training .
SAVE THESE INSTRUCTIONS
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INTRODUCTION
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.
Console
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Top Cover
Bottom Cover
\
Transpor:t Whee I
Handles
/ Slield
SIDEVI~
Left Hanctail
/
LeftPedal
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Figure 1: Major Parts - 4600 Pl/Cl
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INTRODUCTION
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and l ebars
Top cover
Leve l -adju s ting
e nd c ap
Step Cha in
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Figure 2: Major Parts· 4400 PT leL
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INTRODUCTION
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 tile 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:
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Length
Width at Front Leg (4400 PT /CL, 4200 pn
Width at Front Leg (4600 PT /CL)
Height
Weight
4400 PT /CL, 4200 PT
4600 PT/CL
Power Supply Specifications:
4600/4400/4200 PT (U.s ., Canada , Japan)
4600/4400/4200 PT (International)
Batter:y Charger Specifications:
4600/4400 CL (U.s., Canada, Japan)
4600/4400 CL (International)
Internal Batter:y
6 volt, 1 Ah Lead-Acid battery
41 inches (104 cm)
22 inches (56 cm)
32 inches (82 cm)
69 inches (176 cm)
126 pounds (55 kg)
155 pounds (70 kg)
120 VAC, 50/60 Hz, 2.5 Amp
230 VAC , 50/60 Hz , 2.5 Amp
120 VAC, 50/60 Hz, 1 Amp
230 VAC, 50/60 Hz, 1 Amp
PageS

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INSTALLATION INSTRUCTIONS
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.
Rotate cap to adjust
~
LevelAdj ust ing
End
Cop
(24329)
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 alow battery.
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INSTALLATION INSTRUCTIONS
4. If you have a 4600/4400 CL, skip to step 9.If you have a 4600/44001
4200 PT, connect the DC cable of the power supply to the connector
near the bottom of the left side cover (see Figure 4).
power supp ly here
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.
Page 7

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INSTALLATION INSTRUCTIONS
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.
&. WARNING
TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE AND TO
PREVENT SEVERE DAMAGE TO THE MACHINE , USE ONLY THE POWER SUPPLY AP-
PROVED FOR USE WITH THIS EQUIPMENT. IN ADDITION ,
YOUR MACHINE MUST BE PROPERLY GROUNDED .
7. Connect the AC power cord to the AC wa ll outlet. Refer to the
"Grounding Instructions " section if the AC wall outlet does not
accept a three-prong plug.
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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 .
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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 ICl 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 .
PageS