Stairmaster FREECLIMBER 4400 PT/CL User Manual

FREECLIMBER4200 PT, 4400 PT/CL, AND 4600 PT/CLOWNER’S MANUAL®

Page 1WHEN USING ELECTRICAL EQUIPMENT, ALWAYS FOLLOW THESE BASIC PRECAUTIONS:IMPORTANT SAFETY INSTRUCTIONSThis symbol appearing throughout this manual

Page 24. Use this machine only for its intended use as described in this Manual. Donot use parts, attachments, or accessories other than those provide

Page 3Before leaving the manufacturing facility in Tulsa, Oklahoma, yourStairMaster® FreeClimber® exercise system was thoroughly inspected andtested t

Page 4Figure 2: Major Parts - 4200 PT and 4400 PT/CLINTRODUCTION

Page 5Throughout this Manual, all references to the left or right side and to thefront or back are made as if you were on the machine, ready to exerci

Page 6Assemble your machine before use. Machines shipped outside the UnitedStates need to be uncrated before they can be assembled; refer to the“Uncra

Page 74. 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 connectornear th

Page 86. Check to be sure that the input AC power rating marked on the powersupply matches the available power. If it does not, obtain the match-ing p

Page 9GENERAL GUIDELINES FOR SAFE OPERATION1. Obtain a complete physical examination from your medical doctor andenlist a health/fitness professional’

Page 10YOUR FIRST WORKOUT ON THE STAIRMASTER® FREECLIMBER®EXERCISE SYSTEM1. Warm up with light calisthenics and easy stretching exercises for atleast

© 2001 StairMaster Health & Fitness Products, Inc. StairMaster and FreeClimber are registered trademarks or trademarks of StairMaster Health &

Page 11program starts at level three.8. As you become comfortable with exercise motion, press[LEVEL: ∧] and [LEVEL: ∨] to adjust your climbing speed.9

Page 12Head - Keep your chin parallelto the floor. Avoid staring at yourfeet or the computer console. Thisposture will also enhance yourbreathing.Bac

Page 13HEART RATE MONITORINGHEART RATE INPUTContact heart rate and telemetry (e.g., Polar®) heart rate signal detection isavailable. There is no defa

Page 14HEART RATE MONITORING2. There are four options to handle heart rate input signals.Press the [SELECT] key to scroll through the options until yo

Page 15“HOLD HR SENSORS” - In contact heart rate signal situations this messagewill come every 30 seconds to prompt the user to hold the sensors.“HR M

Page 16contact heart rate signals. If you do not see a heart rate on the console, try oneof the following:• Move closer to the console.• Tighten the e

Page 17CONTACT HEART RATEThe StairMaster® FreeClimber® 4600 PT/CL features a digitized contact heartrate monitoring system. Through the use of stainle

Page 18The StairMaster® FreeClimber 4400/4600 PT/CL systems console is dividedinto seven sections: the display window, the workout options, the numeri

Page 19NUMERIC KEYPADThe numeric keypad is located on the right side of the con-sole. Before the exercise program begins, the numbers areused to ente

Page 20WORKOUT STATISTICSDuring the exercise program, the Stats keys are used to track workout statis-tics which are then shown in the display window.

Page ivWARRANTYThis is to certify that the StairMaster® FreeClimber® exercise system is warrantedby StairMaster Health & Fitness Products, Inc. to

Page 21EXERCISE PROGRAM KEYPADThe exercise keypad is located below the display and to the left of the functionkeypad. While the console is in the “SEL

Page 22on the selected intensity level, with 2 levels equating to one vertical bar.The Fat Burner ProgramThe Fat Burner program is a 60-interval worko

Page 23the intensity level during an EXERCISE interval. The intensity level shown dur-ing an EXERCISE interval is indicative of your current speed. Ho

Page 24FREECLIMBER 4400/4600 PT/CL CONSOLETHE FITNESS TEST PROGRAMSUnderstanding Submaximal Exercise TestingBefore using the StairMaster® FreeClimber®

Page 25FREECLIMBER 4400/4600 PT/CL CONSOLE150, external factors no longer influence heart rate, and a linear relationshipexists. As the heart rate ris

Page 26submaximal exercise tests and that person’s heart rate response to a fixedworkload is found to decrease over time, it is reasonably safe to con

Page 27state heart rate of the subject to 110 to 150 beats/min for two consecutivestages. It is important to remember that two consecutive heart rate

Page 28Figure 8: StairMaster® Fitness ProtocolFirst Work Level4 METsIf 100 <= HR <= 120If HR < 100 If HR > 120Second Work Level7 METsSecon

Page 29Table 2. Fitness Rating Norms (VO2max) MEN Age High Good Average Fair Low 20 – 29 >51 51 – 47 47 – 43 42 – 40 <39 30 – 39 >50 50

Page 30intervals at an intensity of 68 steps/min. The CPAT Stair ClimbTest has a total of 10 intervals and lasts for 3 minutes, 20seconds (including w

Page vPREFACERegular use of the StairMaster® FreeClimber® exercise system is a safe andeffective way to develop aerobic fitness while conditioning the

Page 31CONSOLE CODESThere are three groups of console codes which are differentiated according tofunction. The first group of codes are customization

Page 322. Change the units to either Metric or USA units by pressing [LEVEL: ^], [3],[1], [ENTER]. The console will display the current units - either

Page 33[SELECT] “CONTRAST ADJ” 5[SELECT] “MAX SPEED” - N/A- 6[SELECT] “CLINICAL MODE”-N/A-7[SELECT] “SET DEFAULTS “ 9Machine Status Codes[ ^ ] [ 4 ]

Page 34Quick Scan ProgrammingYou can quickly access any of the custom menus by pressing [LEVEL: ^],[4], [ENTER]. The console will then display “MACHIN

Page 35The StairMaster® FreeClimber® 4200 PT console is divided into two LCDdisplay windows. There is a four-function keypad located below the bottomw

Page 36FREECLIMBER 4200 PT CONSOLEcorresponds to Steady Pace, "P3" to Fat Burner, and "P4" to AerobicTraining. The different worko

Page 37BOTTOM WINDOWThe bottom LCD window keeps track of four different statistics during yourworkout: the number of calories burned, the climbing spe

Page 38START/STOP. Press this key while the console is in the ATTRACTmode to begin the workout setup. If pressed at any time duringworkout setup, all

Page 39HELPFUL HINTSRead all maintenance instructions thoroughly before beginning work. In somecases, an assistant is required to perform the necessar

Page 40The 4200 PT console keeps track of the number of hours the machinewas used and the total number of floors climbed. From the ATTRACT mode,press

Page viCONTENTSSAFFETY GUIDELINES ... 1INTRODUCTION ...

Page 412. Inspect the Poly-V belt and HTD belts for excessive wear during thequarterly lubrication. Adjust the belt tension if necessary.LubricationTh

Page 427. Remove the spring pulleys every three months. Clean the springpulley shafts with a dry cloth. Protect the shafts from corrosion with athinco

Page 43MAINTENANCE INSTRUCTIONSTable 3: Recommended Preventive Maintenance Schedule*Note: Use of lubricants other than those specified will result i

Page 44GENERAL TROUBLESHOOTING GUIDELINESThis troubleshooting section is organized into three basic problem sections:electrical troubleshooting, conso

Page 455. Follow the white power connector wire to the where it plugs into themain cable white wire, and disconnect it from the main cablewhite wire.

Page 46• Place a short wire with alligator clips on the B+ terminal and thefield (FLD) terminal of the alternator.• Step on the machine for approximat

Page 473. Step up on the machine. With the voltmeter set to DC voltage, testfor greater than 6.1 VDC in pins #1 (+) and #10 (-) in the main cableconne

Page 48The following tests are performed while the console is in the “SELECTWORKOUT” mode. If the console fails any test, the console should be replac

Page 491. Press [ LEVEL: ^ ], [ 6 ], [ 1 ], to start the test.2. Firmly press each button except [CLEAR]. The name of the key will beshown in the disp

Page 50Tach TestIf you do not have resistance, perform the tach test. The tach test will tell youthe tach signal, in revolutions per minute (RPMs), pi

Page viiCONTENTSThe Fitness Test Programs... 24Understanding Submaximal Exercise Testi

Page 51Contact Heart Rate TestThe contact heart rate system is made up of the console and the contactheart rate sensor handles. Remember that even whe

Page 52Telemetry (Polar®) Heart Rate TestThe telemetry heart rate system is made up of the console, the heart rate re-ceiver, and the chest strap (ava

Page 53If you hear a grinding or clicking noise, experience excessive vibration duringexercise, or if the pedals are not functioning properly, you pro

Page 54• Do not reinstall the Poly-V belt if performing step #4. Plug in theconnector at position J4 or reconnect the DC power cable,as applicable.4.

Page 55• Clean all corrosion off the pedal arm shaft and leveling arm shaftand bushings. Wipe the shafts with an oil-dampened cloth beforereassembling

Page 56COVERSThere are three covers on the 4400 PT/CL and the 4200 PT: the top cover, themid-cover and the bottom cover. The top and bottom covers are

Page 573. 4600 PT/CL: Use the fastener removal tool to release the coverfasteners and separate the top covers.4. To reinstall the 4400 PT/CL and 4200

Page 58CONSOLE1. Remove the four mounting knobs from the back of the console.2. Disconnect the main cable, contact heart rate cables (4600 PT/CL),and

Page 596. Adjust the HTD belt tension so that you have 1/4 inch (0.6 cm) of side-to-side play with fingertip pressure (see Figure 30). The bottom shaf

Page 604. Check to ensure that the spring pulley turns freely and is not wornexcessively. Refer to the “Spring Pulley” section if you have to replacet

Page viiiDiode Test...46Resistor Test...

Page 61SPRING PULLEY1. Remove the bottom cover.2. Unhook the pedal arm return spring from the spring hanger.3. Remove the snap ring from the pulley sh

Page 62TO REDUCE THE RISK OF EYE INJURY, WEAR EYEPROTECTION WHEN REMOVING SNAP RINGS.!WARNING2. Remove the master link from the drive chain.3. Remove

Page 635. Remove the drive chain.6. Remove the sprocket and the other small parts from the left side ofthe hub assembly (see Figure 18).7. Slide the d

Page 64PEDAL1. Remove the snap ring and flat washer from the leveling arm pin andthe pedal shaft (see Figure 17).2. Slide the pedal off the shaft.3. C

Page 65PEDAL ARM1. Remove the pedal and the bottom cover.2. Remove the step chain retainers.3. Support the pedal arm. Unhook the pedal arm return spri

Page 66PARTS REMOVAL AND REPLACEMENTECCENTRIC HUB ASSEMBLY1. Remove the bottom cover.2. Remove the Poly-V and HTD belts.3. Loosen and remove the four

Page 67UPPER HANDLES (4600 PT/CL)1. Disconnect the left and right contact heart rate cables from the backof the console.2. Remove the two mounting scr

Page 68PARTS REMOVAL AND REPLACEMENT5. Tilt the machine forward and use an extended socket to remove thetwo handrail adapter screws from the front leg

Page 69The machine must be grounded if you are using the external power supply orthe battery charger. Grounding provides the path of least resistance

Page 70This equipment has been tested and found to comply with the limits for aClass B digital device, pursuant to Part 15 of the FCC rules. These lim

Page ixFirst Reduction Shaft Assembly ... 66Handlebar (4400 PT/CL, 4200 PT) ...

Page 71APPENDICESIf you need assistance, please have both the serial number of your machineand the date of purchase available when you contact the app

Page 72BATTERY RECYCLINGAfter installing a new battery, Contact the nearest Yuasa-Exide, Inc. recyclingcenter from the list below to get information o

Page 73 STATE ADDRESS PHONE NUMBER New Jersey 131 Industrial Ave. (201) 641-5900Hasbrouck Hgts., NJ 07604 New York 26 Corporate

Page 74APPENDICESFigure 11: Parts Needing Periodic Maintenance

Page 75APPENDICESFigure 12: Final Assembly - Left, 4600 PT

Page 76APPENDICESFigure 13: Final Assembly - Right,4600 PT

Page 77APPENDICESFigure 14: Final Assembly - Left, 4600 CL

Page 78APPENDICESFigure 15: Final Assembly - Right, 4600 CL

Page 79APPENDICESFigure 16: Covers - 4600 PT/CL

Page 80APPENDICESFigure 17: Pedal Arm Assembly & First Reduction Shaft Assembly(4600/4400 PT/CL, 4200 PT)

Page xFigure 12: Final Assembly - Left, 4600 PT ...75Figure 13: Final Assembly - Right, 4600 PT...

Page 81APPENDICESFigure 18:Drive Shaft Assembly & Eccentric Hub Assembly(4600/4400 PT/CL, 4200 PT)

Page 82APPENDICESFigure 19: Final Assembly - Left, 4400/4200 PT

Page 83APPENDICESFigure 20: Final Assembly - Right, 4400/4200 PT

Page 84APPENDICESFigure 21: Final Assembly - Left, 4400 CL

Page 85APPENDICESFigure 22: Final Assembly - Right, 4400 CL

Page 86APPENDICESFigure 23: Covers - 4400 PT/CL, 4200 PT

Page 87APPENDICESFigure 24: Cover Removal

Page 88Figure 25: Cover fastenersAPPENDICES

Page 89APPENDICESFigure 26: Drive Chain tensioning

Page 90APPENDICESFigure 27: Belt Tension