Stairmaster FreeRunner 5400 ESS User manual

F reeRunner
no
5400 ESS
Owner's Manual
~ StairMaster

---------~ - - - ---
P ri nted in the Un i ted States .
°1 998 Sta i rMaster Sports / Med i cal Products , Inc.
All ri ghts reserved .
Corporate Headquaners
12421 Willows Road N.E., Su i te 100
Ki rkland , WA 98034
(800) 635 - 2936
[phone]
Fax (425 ) 823-9490
tairMaster
PINZ7027·B
10 1998 Sta ir Master Sports/Medical Products , Inc.lS t ai r Master . ~. t"". and FreeRunner are
registered trademarks or trademarks of St airMaster Sports/Medical Pr od u cts . Inc. in the United
St ates and / or other countries .
Page iii

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
best prices available.
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 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
seasonal promotions .
Pageiv

A FULL LINE OF EXCEPTIONAL PRODUCTS
STAIRCLIMBERS
The Best in the Industry
Our popular FreeClimber ~ stairclimber
line - with upr i ght handlebars and a
rail-less design - now offers you 3
different models to choose from. These
models include the fully featured
FreeClimber 4400 PT, the cordless
FreeClimber 4400 CL with Polar ~ Heart
Rate Monitor, and the cost-efficient
FreeClimber 4200 PT - designed
especially for health clubs .
Other StairMaster ~ stairclimbers
include the Stepm i ll ~ 7000 PT - for the
most challenging stairclimbing
workout - as well as the legendary
Sta i rMaster 4000 PT ~ .
ELLIPTICAL STRIDING SYSTEMS
The New StairMaster FreeRunner
Introducing the StairMaster FreeRun-
ner '" 5400 ESS - a revolut i onary new
design that allows you to vary your
stride length from 10" to 40 ." Not only
does this unique VSL feature accom-
modate all users ,it also provides
enhanced lower-body conditioning -
with greater involvement of the glutes ,
quadriceps, and hamstrings.
For total-body conditioning , club
members wi II 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 v

A FULL LINE OF EXCEPTIONAL PRODUCTS
TREADMILLS
The Highest Ouality
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
three different models to choose from
- the ClubTrack ~ , the HR ClubTrack ~
and the HR Club Track Plus
lM
• Only
Quinton could match the StairMaster
reputation 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.

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 vii

WARRANTY
This is to certify that the StairMaster @ FreeRunner™ 5400 ESS elliptical system is
warranted by StairMaster 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 nontransferable from the original owner.
If, within three years from the date of purchase, any part of the StairMaster
FreeRunner elliptical system should fail to operate properly (except any accessories),
contact our Customer Service Department to report the problem . When calling , please be
prepared to provide the customer service representative with the following information :
• Your name, 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 billing address.
This information will ensure that you are the only one ordering parts under your
warranty agreement. If warranty replacement parts are shipped to you, you may be
required 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 for a machine that is less 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 such inoperable
warranty parts. Detailed instructions are included with each warranty
replacement part .
StairMaster Sports/Medical Products, Inc . neither makes, assumes, nor authorizes
any representative or other person to make or assume for us any other warranty whatso-
ever , 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 Sports/Medical Products, Inc. are used.
Note: Aerosol products cannot be transported via air.
Page viii

PREFACE
Regular use of the StairMaster FreeRunner ™ 5400 ESS 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 pre-
sented 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 important phone numbers, additional
instructional illustrations, and wiring diagrams.
Throughout this manual, the 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 the [MANUAL] key to select the MANUAL workout
option .
WHAT IS THE STAIRMASTER FREERUNNER ELLIPTICAL STRIDING
SYSTEM?
The StairMaster FreeRunner 5400 ESS is an elliptical striding system that
allows users to simulate the natural movement path of running withoutjoint
impact or trauma . With its patent pending VSL (Variable Stride Length) technol-
ogy, the FreeRunner permits users to adjust their stride lengths from 10" to 40."
The FreeRunner also has retractable handles to provide users with the options of
lower body only or total body workouts. Another feature of the FreeRunner is
Polar ® and contact heart rate monitoring.
Pageix

CONTENTS
SAFETY GUIDELINES 1
INTRODUCTION 3
INSTALLATION INSTRUCTIONS 5
BASIC OPERATING PROCEDURES 10
General Guidel i nes f or Safe Operat i on 10
Your First Workout 11
CONTACT HEART RATE 15
POLAR® HEART RATE 16
CONSOLE 17
Text Ba r 17
Di splay 17
Function Keypad 18
Exerc i se Program Keypad 20
Custom Exerc i se Programs 21
Custom Scrol li ng Message 22
Ed i ting the Scrolling Message 23
Chang i ng t he Console Un i ts & Prompt Language 24
Conso le Codes 24
The Jackpot Option 26
MAINTENANCE INSTRUCTIONS 27
Helpful Hi nts 27
Tool List 27
Ma i ntenance Records 27
Initial Serv i ce 28
Preventive Maintenance 28
TROUBLESHOOTING 31
Genera l Troub l eshoot i ng Gu i del i nes 31
Systemat icEl ectr i cal Troubleshoot i ng 31
Conso leDi agnost ic Tests 34
Systematic Mechanical Troub l eshoot i ng 36
Page x

CONTENTS
PARTS REMOVAL AND REPLACEMENT 38
Alternator 38
Bearings 39
Bearing Blocks - Heel Link 39
Bearing Blocks - Leg Assembly 39
Pillow Block Bearings - Heel Link 40
Pillow Block Bearings - Leg Assembly 40
Belts 40
Upper POly- V Belt 40
Lower POly- V Belt 41
Brake System 42
Brake Actuator Arm 42
Brake Motor 42
Brake 43
Cables 44
Alternator Cable 44
Contact Heart Rate Cable 44
Polar ® Heart Rate Cable 45
Upper Main Cable 45
Upper Brake Cable 46
Lower Brake Cable 46
Lower Main Cable 46
Limit Switch Cable 47
Power Connector Cable 49
Stride Sensor Cable 49
Chains 49
Upper Heel Link Chains 49
Lower Heel Link Chains 50
Front Drive Chain Assembly 51
Rear Drive Chain Assembly 52
Step Chains 52
Console 53
Console Handlebar 53
Page xi

CONTENTS
Covers 54
Base Cover 54
Heel Link Pivot Cover 54
Safety Panel 54
Side Cover 54
Step Cover 55
Top Cover 55
Drive Shaft Assembly 55
Handle Assembly 56
Handle Knob Assembly 56
Heel Link 57
Heel Link Pivot Assembly 57
Leg Assembly 58
Load Resistor 58
Mounting Blocks 59
Pedal Assembly 59
Pedal Return Springs 60
Power Control Board 60
Pulleys 61
Idler Pulley Assembly 61
Intermediate Poly-V Pulley Assembly 62
Lower POly-V Pulley 62
Rear Support Bar 62
Step 63
Stride Sensor 63
Spring Cartridge 64
Sprockets 64
Drive Chain Idler Sprockets and Heel Link Idler Sprockets 64
Drive Sprockets 65
Upper Heel Link Idler Sprockets 65
Leg Assembly Sprockets 66
Turnbuckle Assembly Adjustment 66
GROUNDING INSTRUCTIONS 67
NOTICE OF FCC COMPLIANCE 68
Page xii

CONTENTS
APPENDICES
Important Phone Numbers 69
Figures 19-38 89
LIST OF TABLES
Table 1: Dimensions and Specifications 4
Table 2: Character Codes for the Scrolling Message 23
Table 3: Console Codes 25
Table 4: Recommended Preventive Ma i ntenance Schedule 30
LIST OF ILLUSTRATIONS
Figure 1: Major Parts 3
Figure 2: Shipp i ng Components 5
Figure 3: Tywrap Location 6
Figure 4: Cable Locations 7
Figure 5: Level Adjusting End Caps 8
Fi
gure 6: DC Power Connector 9
Figure 7: Correct Foot Placement 12
Figure 8: Handle Adjustment 13
Figure 9: Correct Exercise Position 14
Figure 10 : Contact Heart Rate Sensors 15
Figure 11: Polar ® Heart Rate Receiver 16
Figure 12 : 5400 Console Diagram 17
Figure 13: Alternator Mounting 38
Figure 14 : Belt Location 41
Figure 15 : Brake Location 43
Figure 16 : Limit Switch Assemb ly 48
Figure 17: Upper Heel Link Chains 50
Figure 18: Ground i ng System 67
Fi gure 19 : Final Assembly - Left Side 70
Figure 20: Final Assembly - Right Side 71
Figure 21 : Chain Assembl i es 72
Figure 22 : Belt Tension 73
Figure 23: Dr i ve Shaft Assembly 74
Figure 24: Leg Assembly 75
Page xiii

CONTENTS
Figure 25: Heel Link Assembly 76
Figure 26 : Pedal Mounting 77
Figure 27: Pedal Assembly 78
Figure 28: Master Links 79
Figure 29 : Heel Link Pivot Adjustment 80
Figure 30 : Handle Assembly 81
Figure 31: Limit Switch Assembly 82
Figure 32: Power Control Board "A" 83
Figure 33 : LED Panel 84
Figure 34 : Power Control Board " B" 85
Figure 35 : Console Main Cable 86
Figure 36: Alternator Cable 87
Figure 37 : Power Supply 88
Figure 38 : Load Resistor 89
Page xiv

SAFETY GUIDELINES
WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:
IMPORTANT SAFETY INSTRUCTIONS
Ji'. This symbol appearing throughout this manual means
L.l.1 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.
& 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.Cl
ose supervision is necessary whenever the machine is used by or near
children ,i nvalids , or disabled persons .
Page 1

SAFETY GUIDELINES
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.
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
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 . Do not use the machine outdoors .
The safety level given by the design of this equipment can only be main-
tained 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 .
I SAVE THESE INSTRUCTIONS
Page 2

INTRODUCTION
Before leaving the manufacturing facility in Tulsa, Oklahoma , your
StairMaster ® FreeRunner ™elliptical striding system was thoroughly inspected
and tested to ensure proper operation. The major parts of the machine are shown
in Fi gure 1.
GUARD COVER ---I--I--+l-~W
(PN 22798 . RIGHT)
(PN 22799 . LEFT)
TRANSPORT
WHEELS
Figure 1: Major Parts
Page 3

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 l ocated on the front of the machine . The dimens i ons and
genera l specifications of the machine are li sted in Table 1.
Table 1. Dimensions and Specifications for the StairMaster®
FreeRunner™ Elliptical Striding System
Physical Dimensions:
Height
Depth
Width
Weight
65 . 5" (166 cm)
42.0"(107 cm)
53.0 " (135 cm)
460 .0 Ibs (209 kg)
Range of Motion:
Maximum stride len gth
Peak elliptical pattern
54 "
12 \\ - 36 "
Power Supply Specifications*:
Input Voltage
Output Current Capac ity
Input Power Consumption
110-120 VAC , 50/60 Hz
2.5 Amps
55 Watts
* Opt i onal power supplies , inten ded for use outside the United States, are
available for 220 - 240 VAC, 50 / 60 Hz power requirements.
Page 4

INSTALLATION INSTRUCTIONS
Your FreeRunner™ is shipped co mplete with all pa rt s re q uired fo rasse mbly.
S tudy the assembly instuctions c arefully. The shipping co mp one nt s ar esho wn
below in Figure 2. Contact our Customer S ervice D epartment at (8 00 ) 33 1 -3578
for assistance . International customers should contact their l oc al di s tribut o rs .
\ \=- _ ~_----\ ~--- READING RACK
( PN 22775 )
CONSOLE KNOB
(4X PN 24677 )
LOCK WASHER
(4X PN 22138 )
CONSOLE HANDLEBAR
MOUNTING SCREWS
(18 X PN 25176)
CD
Figure 2: Shipping Components
Page 5

INSTALLATION INSTRUCTIONS
A. Assemble the Machine:
1. Cut each tywrap that secures the console handlebar to the rear support
bars (see Figure 3). Remove the foam protection from each side of the
handlebar. Lift the handlebar out from under the pedals . Set the handlebar
with console aside. Remove the step cover from under the pedals and set
the cover aside .
TYWRAP
CONSOLE
Figure 3: Tywrap Location
2. Remove the shrink wrap from the pedal, and lift the power supply box,
owner 's manual, and hardware bag off the pedal. Set the parts aside.
3. Remove the top covers. Use the fastener removal tool from the hardware
bag to remove the top cover rivets . Disconnect the Polar Q!) heart rate receiver
from under the right top cover (see Figure 4) .
4.
Have an assistant support the console handlebar. Stand on the right side of
the mach i ne and connect the plug-in Polar cable from the handlebar to the
upper Polar cable in the frame . Connect the Polar heart rate cable to the
heart rate receiver and reinstall the top cover (see Figure 4) .
5.
Stand on the left side of the machine and connect the upper main cable to
the lower main cable . Next , connect the upper brake cable to the lower
brake cab le. Tuck any excess slack in the cables up inside the handlebar .
Page 6

INSTALLATION INSTRUCTIONS
6. Attach the console handlebar to the frame. To prevent the rivnuts (see
Figure 4) from spinning in the frame, hold the rivnuts with pliers while
securing the mounting screws to the frame.
POLAR@ HEART RATE RECEIVER
(PN 25165)
TOP COVER
BRAKE CABLES D~/ __ -+
"NOTE: KEEP EXCESS SLACK IN CABLES AWAY FROM THE LEG SPROCKETS.
Figure 4: Cable Locations
7. Have an assistant help you slide the machine off the shipping pallet and
onto the floor. Use the transport wheels (see Figure 1) to roll the machine
into the desired location .
8. Remove the packing material from the console, handlebar, and step cover.
Place the step cover over the step and insert a mounting screw and a
washer into each cover hole . Tighten each screw with the 5/32" allen
wrench .
Page 7