Stairmaster FREERUNNER 5600 Owner's Manual
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Stairmaster FREERUNNER 5600 Owner's Manual

Stairmaster FREERUNNER 5600 Owner's Manual

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  • Page 1 5600 ® UNNER ’ WNER ANUAL...
  • Page 2 P/N 22870-A © 2001 StairMaster Health & Fitness Products, Inc., StairMaster, and FreeRunner are registered trademarks or trademarks of StairMaster Health & Fitness Products, Inc. in the UnitedStates and/or other countries. StairMaster is a Rutledge Capital company. Page iii...
  • Page 3 This is to certify that the StairMaster® FreeRunner™ 5600 ESS elliptical system is warranted by StairMaster Health & Fitness 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.”...
  • Page 4 WHAT IS THE STAIRMASTER FREERUNNER ELLIPTICAL STRIDING SYSTEM? The StairMaster FreeRunner 5600 ESS is an elliptical striding system that allows users to simulate the natural movement path of running without joint impact or trauma. With its patent pending VSL (Variable Stride Length) technol- ogy, the FreeRunner permits users to adjust their stride lengths from 10”...

  • Page 5: Table Of Contents

    TELEMETRY (POLAR HEART RATE ............17 Using the transmitter Belt ..............17 Maintaining the Transmitter Belt ............18 FREERUNNER 5600 ESS CONSOLE ............19 The Display Window ................19 The Numeric Keypad ................20 The Entertainment Keypad ..............20 The Intensity Level Keys ................. 20 The Stop Key ..................
  • Page 6 CONTENTS Quick Scan Programming ..........32 Machine Status Codes ..............33 Quick Scan Programming ..........34 Configuration Codes ............... 34 MAINTENANCE INSTRUCTIONS ............. 35 Helpful Hints ................... 35 Tool List ....................35 Maintenance Records ................35 Initial Service ..................36 Preventive Maintenance ................
  • Page 7 CONTENTS Alternator Cable ................59 Upper Main Cable ................59 Lower Brake Cable ................60 Lower Main Cable ................60 Limit Switch Cable ................60 Power Connector Cable ..............62 Stride Sensor Cable ................ 63 Chains ..................... 63 Upper Heel Link Chains ..............63 Lower Heel Link Chains..............
  • Page 8 Figure 6: DC Power Connector ..............9 Figure 7: Correct Foot Placement ............12 Figure 8: Transmitter Belt ................ 16 Figure 9: The FreeRunner 5600 ESS Console .......... 19 Figure 10: StairMaster Fitness Protocol ..........29 Figure 11: Alternator Mounting............... 53 Figure 12: Belt Location ................
  • Page 9 CONTENTS Figure 16: Grounding System ..............81 Figure 17: Final Assembly - Left Side ............84 Figure 18: Final Assembly - Right Side ........... 85 Figure 19: Chain Assemblies ..............86 Figure 20: Belt Tension ................87 Figure 21: Drive Shaft Assembly ............. 88 Figure 22: Leg Assembly .................

  • Page 10: Safety Guidelines

    SAFETY GUIDELINES HEN 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 —...
  • Page 11 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. Connect the power supply cord to a properly grounded AC wall outlet;...

  • Page 12: Introduction

    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 Figure 1. Figure 1: Major Parts...

  • Page 13: Table 1: Dimensions And Specifications

    For example, the console is located on the front of the machine. The dimensions and general specifications of the machine are listed in Table 1. ® Table 1. Dimensions and Specifications for the StairMaster ® FreeRunner Elliptical Striding System...

  • Page 14: Installation Instructions

    INSTALLATION INSTRUCTIONS ® Your FreeRunner is shipped complete with all parts required for assembly. Study the assembly instructions carefully. The shipping components are shown below in Figure 2. Contact our Customer Service Department at (800) 331-3578 for assistance. International customers should contact their local distributors. READING RACK (PN 22775) CONSOLE...

  • Page 15: Figure 3: Tywrap Location

    INSTALLATION INSTRUCTIONS A. Assemble the Machine: 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.

  • Page 16: Figure 4: Cable Locations

    INSTALLATION INSTRUCTIONS lower brake cable from the frame. Tuck any excess slack in the cables up inside the handlebar. 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.

  • Page 17: Figure 5: Level Adjusting End Caps

    INSTALLATION INSTRUCTIONS B. Level the Machine: Make sure the machine is level before you use it for the first time. The rubber end caps (see Figure 5) are designed to compensate for uneven floors. Each face of the caps is a different thickness. Twist the caps to stabilize the machine.

  • Page 18: Figure 6: Dc Power Connector

    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 Health & Fitness Products, Inc. before proceeding any further.

  • Page 19: Basic Operating Procedures

    ® Although all equipment manufactured by StairMaster Health & Fitness Products, Inc. has been thoroughly inspected by the manufacturing facility prior to shipment, proper installation and regular maintenance are required to ensure safety.

  • Page 20: Your First Workout

    BASIC OPERATING PROCEDURES ® ® YOUR FIRST WORKOUT ON THE STAIRMASTER FREERUNNER ELLIPTICAL STRIDING SYSTEM Basic Instructions for First-Time Users Warm up with light calisthenics and easy stretching exercises for at least five minutes before beginning your exercise program. WARNING...

  • Page 21: Figure 7: Correct Foot Placement

    BASIC OPERATING PROCEDURES Figure 7: Correct Foot Placement for Stepping ® onto the FreeRunner Pedals Select the MANUAL exercise program so that you can control the pace of your first workout and get accustomed 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.
  • Page 22 BASIC OPERATING PROCEDURES Begin Exercising Lean forward and take running strides without overextending your legs. The MANUAL program starts at intensity level 3. Adjust the intensity level up or down as desired. Relax and stand up straight while exercising. Use the handles for balance.

  • Page 23: Heart Rate Monitoring

    HEART RATE MONITORING HEART RATE INPUT ® ® The FreeRunner 5600 console features telemetry (e.g., Polar ) heart rate signal detection. There is a short “lock out” period at the beginning of each workout session during which the console first detects a signal and then validates the signal type.

  • Page 24: Error Messages

    HEART RATE MONITORING “ BOTH NOT LOCKED” - allows either telemetry or contact heart rate signals to be detected. Does not lock out a particular input signal for the entire workout. This option will detect either input signal during a workout session, but only one at a time, and only until the other signal terminates.

  • Page 25: Telemetry (Polar ®) Heart Rate

    TELEMETRY HEART RATE TELEMETRY HEART RATE ® ® ® The StairMaster FreeRunner 5600 features telemetry (Polar ) heart rate monitoring. The system consists of the receiver, located in the console and a transmitter belt (purchased separately) worn across your chest. The monitoring function is activated as soon as you strap on the chest belt and step within range of the receiver in the machine.

  • Page 26: Maintaining The Transmitter Belt

    Do not use abrasives or chemicals such as steel wool or alcohol for cleaning, as they can damage the electrodes permanently. You can order replacement belts from StairMaster, Polar Electro, Inc., or your local fitness store: StairMaster 800-331-3578 P/N 64000 Polar Electro, Inc.

  • Page 27: Freerunner 5600 Ess Console

    FREERUNNER 5600 ESS CONSOLE The StairMaster ® FreeRunner 5600 ESS systems console is divided into seven sections: the display window, the workout options, the numeric keypad, the en- tertainment keypad, the workout statistics, the stop key, and the intensity level keys (see Figure 9).

  • Page 28: The Numeric Keypad

    FREERUNNER 5600 ESS CONSOLE THE NUMERIC KEYPAD The numeric keypad is located on the right side of the console. Before the exercise program begins, the numbers are used to enter data in response to the console prompts. • Enter - Confirms workout selections and stores the informa- tion used by the console to calculate workout statistics.
  • Page 29 FREERUNNER 5600 ESS CONSOLE WORKOUT STATISTICS During the exercise program, the Stats keys are used to track workout statistics which are then shown in the display window. Pressing the [SELECT] key turns off the scanning feature and shows the statistic of choice in the display window.

  • Page 30: The Quick Start Program

    FREERUNNER 5600 ESS CONSOLE EXERCISE PROGRAM KEYPAD The exercise keypad is located below the display and to the left of the function keypad. While the console is in the “SELECT WORKOUT” mode, press one of the exercise program keys to preview the desired workout. There are six workout...

  • Page 31: The Fat Burner Program

    FREERUNNER 5600 ESS CONSOLE on the selected intensity level, with 2 levels equating to one vertical bar. The Fat Burner Program The Fat Burner program is a 60 interval workout designed for people just starting a weight control program. The relative intensity level is indicated on the...

  • Page 32: The Constant Heart Rate Program

    FREERUNNER 5600 ESS CONSOLE during an EXERCISE interval. The intensity level shown during an EXERCISE inter- val is indicative of your current speed. However, the current speed during a REST interval is equal to a scaled percentage of the displayed intensity level. Note that the program profile does not change at any time during the workout session.

  • Page 33: The Fitness Test Program

    The Fitness Test Programs Understanding Submaximal Exercise Testing Before using the StairMaster FreeClimber for submaximal exercise testing, it should be noted that all submaximal fitness tests make several assumptions: • That a steady-state heart rate is obtained for each exercise workload.
  • Page 34 FREERUNNER 5600 ESS CONSOLE no longer influence heart rate, and a linear relationship exists. As the heart rate rises above 150, the heart rate-oxygen uptake relationship becomes curvilinear. The third assumption involves maximal heart rate. Maximal heart rate is the greatest heart rate that can be measured when an individual is exercising to the point of volitional fatigue (i.e., exhaustion) during a graded exercise test.

  • Page 35: Pretest Screening

    The StairMaster Submaximal Fit Test The StairMaster branching protocol is a series of 3-minute stages of continuous exercise at increasing intensity. The first stage is a warm-up at ap- proximately 4 METs. The intensity of the remaining stages is based on the heart rate response to the warm-up.
  • Page 36 2max The test typically lasts from 9 to 15 minutes. In the StairMaster protocol, each work rate is performed for 3 minutes, with heart rates recorded during the final 4 seconds of the second and third minutes of each stage. If the heart rates are within 5 beats/min, then the heart rate during the last minute is plotted against the work rate, and the pro- gram advances to the next 3-minute stage.

  • Page 37: Figure 10: Stairmaster Fitness Protocol

    FREERUNNER 5600 ESS CONSOLE ® Figure 10: StairMaster Fitness Protocol FIT TEST PROTOCOL StairMaster CV Products First Work Level 4 METs If HR < 100 If 100 <= HR <= 120 If HR > 120 Second Work Level Second Work Level...

  • Page 38: Table 2: Fitness Rating Norms

    FREERUNNER 5600 ESS CONSOLE Table 2. Fitness Rating Norms (VO 2max High Good Average Fair 20 – 29 >51 51 – 47 47 – 43 42 – 40 <39 30 – 39 >50 50 – 45 45 – 41 41 – 37 <37...

  • Page 39: Console Codes

    FREERUNNER 5600 ESS CONSOLE CONSOLE CODES There are three groups of console codes which are differentiated according to function. The first group of codes are customization codes and are used to set defaults such as units, language, heart rate input type, etc. The second group of codes are machine status codes and are used to track hours and other general usage patterns for maintenance purposes.

  • Page 40: Quick Scan Programming

    FREERUNNER 5600 ESS CONSOLE 2. Change the units to either Metric or USA units by pressing [LEVEL: ^], [3], [1], [ENTER]. The console will display the current units - either “USA UNITS” or “METRIC UNITS.” Use the [SELECT] key to change option, and then press [ENTER].

  • Page 41: Machine Status Codes

    FREERUNNER 5600 ESS CONSOLE [SELECT] “CONTRAST ADJ” [SELECT] “MAX SPEED” - N/A- [SELECT] “CLINICAL MODE”-N/A- 7 [SELECT] “SET DEFAULTS “ Machine Status Codes [ ^ ] [ 4 ] [ 0 ] display machine run time in hours [ ^ ] [ 4 ] [ 1 ] display number of workouts...

  • Page 42: Quick Scan Programming

    FREERUNNER 5600 ESS CONSOLE Quick Scan Programming You can quickly access any of the custom menus by pressing [LEVEL: ^], [4], [ENTER]. The console will then display “MACHINE STATUS”. Scroll through the following options: [ SELECT ] “ RUN HOURS XXXX”...

  • Page 43: Maintenance Instructions

    MAINTENANCE INSTRUCTIONS HELPFUL HINTS Read all maintenance instructions thoroughly before beginning work. In some cases, an assistant is required to perform the necessary tasks. 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.

  • Page 44: Initial Service

    MAINTENANCE INSTRUCTIONS INITIAL SERVICE Upon receiving your machine, use a soft, clean towel to wipe off the dust that may have accumulated during shipping. Your new machine will require minor as- sembly. Refer to the “Installation Instructions” section for details. PREVENTIVE MAINTENANCE A schedule for the recommended preventive maintenance is shown in Table 4.

  • Page 45: Lubrication

    Remove the covers to access the components. Place a protective mat on the floor while you lubricate your machine. ® A rubber floor mat is available from StairMaster Health & Fitness Products, Inc. Each week lubricate the entire length of the chains, and around each sprocket with an aerosol synthetic chain lubricant (e.g.

  • Page 46: Table 3: Recommended Preventive Maintenance Schedule

    MAINTENANCE INSTRUCTIONS Table 3. Recommended Preventive Maintenance Schedule s t l u j d y r e t n o n o i s r u s r e s n i y l i , r e t u l d l o a e l r e n...

  • Page 47: Troubleshooting

    TROUBLESHOOTING GENERAL TROUBLESHOOTING GUIDELINES This troubleshooting section is organized into five basic sections: Basic Electrical Theory, the Power Control Board, the Systematic Electrical Troubleshooting, Con- sole Diagnostic Tests, and Systematic Mechanical Troubleshooting. Perform the tests in exactly the same order as written. Refer to the “Parts Removal and Re- placement”...

  • Page 48: Troubleshooting

    TROUBLESHOOTING LED #1 - V Supply The purpose of this LED is to show whether or not power is reaching the power control board. If this LED is not illuminated, then there is no power to the power control board. The console will be off and the other nine LEDs will not be illuminated.
  • Page 49 TROUBLESHOOTING intensity level increases. If the LED is off, check the console and the upper and lower main cables. If the LED is illuminated and you still experience resistance problems, check the power control board, load resistor wires, load resistor, and the alternator. LED #5 - SS The purpose of the “SS,”...
  • Page 50 TROUBLESHOOTING LED #8 and LED #9 These last two LEDs are used for indicating that the brake system is being activated using the upper and lower limit switches. The LEDs remain illuminated at all times (except while the brake motor is in motion).

  • Page 51: Systematic Electrical Troubleshooting

    TROUBLESHOOTING SYSTEMATIC ELECTRICAL TROUBLESHOOTING The electrical system has six major components: the power supply, the power cables, the alternator, the power control board, the console, and the load resistor. In order to identify the component that is causing the problem, you must system- atically test the entire system.
  • Page 52 TROUBLESHOOTING Locate the black and white power connector wires on the power control board. Unplug the connector from the board and verify approx. 15-16 VDC between pin #1 (negative) and pin #2 (positive). Replace the power connector if the reading is under the specified range or no voltage reading at all.
  • Page 53 TROUBLESHOOTING • Place alligator clips on the B+ terminal and the field terminal of the alternator. • Step on the machine for 15 - 20 seconds. • If resistance is achieved during this time, your alternator has correct current flow. •...
  • Page 54 [STOP] while in the DIAGNOSTIC mode. Please note that there may be addition verbiage on the display other than is listed in this manual. The FreeRunner ® console is used on other StairMaster equipment. Diagnostic Codes [ ^ ] [ 6 ] [ 0 ] Test display...
  • Page 55 TROUBLESHOOTING Firmly press each button except [CLEAR]. The name of the key will be shown in the display window. Press [CLEAR] to end the test. The Serial Port Test This test verifies that the RS 232 port used for linking to commercial entertain- ment systems is working.
  • Page 56 TROUBLESHOOTING The Brake Tests Use this test to verify that the brake limit switches are triggered correctly. Adjust the limit switches if these tests fail. For replacement procedures refer to the cable section of “Parts Removal and Replacement. “ Continuous cycle verification: Remove the left side cover.
  • Page 57 TROUBLESHOOTING Error Reporting The console will display various error messages in the display window. The total amount of errors will be displayed in the upper right numeric window. Note that only the highest priority reported error will be displayed. Errors are handled in two ways.
  • Page 58 TROUBLESHOOTING ® Telemetry (Polar ) Heart Rate The telemetry heart rate system is made up of the console, the heart rate re- ceiver, and the chest strap (available separately). You can test each component by performing the following steps: You will need to put a chest strap on in order to test the telemetry heart rate.
  • Page 59 TROUBLESHOOTING tarily cause errant heart beat detection - this is normal. If excessive false heart beats appear only during workouts, remove the console and verify that the main cable is not curled up behind it. Tuck as much of the main cable length inside the handlebar as possible before replacing the console.

  • Page 60: Systematic Mechanical Troubleshooting

    TROUBLESHOOTING SYSTEMATIC MECHANICAL TROUBLESHOOTING If you hear a grinding or clicking noise or experience excessive vibration during exercise, a problem exists in the drive train of your machine. Isolate the problem area by performing the following tests in precisely the order listed below. Refer to the appropriate “Parts Removal and Replacement”...
  • Page 61 TROUBLESHOOTING Rotate the drive sprockets (see Figure 19). Each sprocket should lock in one direction and rotate freely in the reverse direction. Inspect the drive shaft for wear when replacing a failed clutch sprocket. Check the pedal shafts and bushings by removing the pedal (see Figure 22).

  • Page 62: Parts Removal And Replacement

    PARTS REMOVAL AND REPLACEMENT ALTERNATOR Remove the left side cover. Mark the location of each wire attached to the alternator (see Figure 34). Remove the wires and the diode from the alternator. Remove the brake mounting bolt from the alternator (see Figure 11). Remove the alternator adjusting bolt from the slotted brace (see Figure 11).

  • Page 63: Bearings

    PARTS REMOVAL AND REPLACEMENT BEARINGS Bearing Block – Heel Link Remove the side cover. Remove the pedal shaft housing from the pedal and pivot the pedal forward. Remove the heel link flange bearing, jam nut, and heel link sprocket. Use the heel link turnbuckle to loosen the heel link chain. Keep track of the shaft key.

  • Page 64: Flange Bearings - Heel Link

    PARTS REMOVAL AND REPLACEMENT Flange Bearing – Heel Link Remove the appropriate side cover. Loosen the two set screws on the flange bearing. Remove the two mounting screws and washers from the bearing housing and slide the flange bearing assembly off the heel link shaft.

  • Page 65: Lower Poly-V Belt

    PARTS REMOVAL AND REPLACEMENT Loosen the alternator screw and mounting bolt. Pivot the alternator down. Remove the upper Poly-V belt (see Figure 12). Reinstall the belt. Pivot the alternator up or down as necessary to allow ¼” (0.6 cm) deflection at the midpoint between the two pulleys (see Figure 20).

  • Page 66: Brake System

    PARTS REMOVAL AND REPLACEMENT BRAKE SYSTEM Brake Actuator Arm Remove the left side cover. Remove the brake cam mounting screw from the top of the brake actuator arm. Loosen the jam nut from the center of the actuator arm, and remove the lower screw (see Figure 13).

  • Page 67: Brake

    PARTS REMOVAL AND REPLACEMENT “Brake Off” Brake Motor Switch Brake Cam Brake Cam Mounting PN 21840 Screw “Brake On” Switch Brake Brake Actuator Arm PN 25588 PN 22791 Jam Nut Lower Bolt Figure 13: Brake Location Brake Remove the left side cover. Remove the brake actuator arm from the brake.

  • Page 68: Cables

    PARTS REMOVAL AND REPLACEMENT CABLES Alternator Cable Remove the left side cover. Unplug the alternator cable from the power control board. Remove the wiring from the alternator, noting the origin and color of the wires removed from each terminal. Install the new cable and verify the wiring connections (see Figure 34).

  • Page 69: Lower Brake Cable

    PARTS REMOVAL AND REPLACEMENT Lower Brake Cable Remove the left side cover. Disconnect the upper brake cable from the lower brake cable. Unplug the lower motor cable from the power control board. Install the new cable and reinstall the side cover. Lower Main Cable Remove the left side cover and disconnect the upper main cable from the lower main cable.
  • Page 70 PARTS REMOVAL AND REPLACEMENT Use the mounting screws to adjust the upper and lower limit switches so that the brake cam triggers the limit switches first before it hits the mechanical stops (see Figure 14). Turn the power on. Press [ LEVEL: ^ ], [ 6 ], [ 5 ], [ENTER] to start the test.

  • Page 71: Power Connector Cable

    PARTS REMOVAL AND REPLACEMENT Motor Cable Limit Switch Brake Off Switch Trigger Points Brake On Switch Mechanical Stops Figure 14: Limit Switch Assembly Power Connector Cable Remove the left side cover. Unplug the power connector from the power control board. Page 62...

  • Page 72: Stride Sensor Cable

    PARTS REMOVAL AND REPLACEMENT Remove the four mounting screws and grounding screw from the frame. Remove the power connector cable from the frame. Install the new cable, secure the grounding screw, and reinstall the side cover. Stride Sensor Cable Remove the left side cover. Unplug the cable from the stride sensor board.

  • Page 73: Lower Heel Link Chains

    PARTS REMOVAL AND REPLACEMENT Reinstall the heel link and ensure that the heel link shaft key is fully inserted into the key way. Reconnect the extension spring to the frame. Adjust top edge of the heel link pivot assembly so that it is parallel with the floor (see Figure 27).

  • Page 74: Front Drive Chain Assembly

    PARTS REMOVAL AND REPLACEMENT Disconnect the single pitch master links from each end of the chain. Pull the chain away from the lower heel link sprocket. Install the new chain. Adjust the top edge of the heel link pivot assembly so that it is parallel with the floor (see Figure 27). Reinstall the covers.

  • Page 75: Step Chains

    PARTS REMOVAL AND REPLACEMENT Rotate the drive chain turnbuckle to loosen the drive chain assembly. Remove the rear drive chain master links from each leg sprocket. Remove each pedal spring from the spring hanger and disconnect each step chain from each drive chain adapter link. Disconnect the master links from each end of the chain adapter links, and pull the lower chain out from under the drive chain idler sprockets (see Figure 21).

  • Page 76: Console

    PARTS REMOVAL AND REPLACEMENT Pull the chain away from the drive sprocket and install the new chain. Reinstall the spring and verify that the spring is seated in the spring hanger groove. Note: If you are having difficulty removing the left spring, remove the power control board for more accessibility.

  • Page 77: Covers

    PARTS REMOVAL AND REPLACEMENT COVERS WARNING TO REDUCE THE RISK OF INJURY, DO NOT OPERATE THE MACHINE WHILE THE COVERS ARE REMOVED. DO NOT MOVE THE PEDALS WHILE ANYONE’S HANDS ARE INSIDE THE MACHINE. Base Cover Remove the side covers. Remove the two mounting rivets located on the lower front side of the frame.

  • Page 78: Drive Shaft Assembly

    PARTS REMOVAL AND REPLACEMENT Lift the side cover up and remove it from the frame. Install the new side cover by aligning the cover hooks with the frame pins and tightening the wing nuts. Reinstall the top cover. DRIVE SHAFT ASSEMBLY Remove all the covers.

  • Page 79: Handle Knob Assembly

    PARTS REMOVAL AND REPLACEMENT HANDLE KNOB ASSEMBLY Remove the handle assembly. Remove the shoulder washer from each side of the handle yoke (see Figure 28). Pull the handle adjustment knob out and slide the yoke out of the handle. Remove the knob. Do this by inserting a phillips screwdriver or small shaft into the handle knob pin to prevent it from spinning while you rotate the knob counterclockwise.

  • Page 80: Heel Link Pivot Assembly

    PARTS REMOVAL AND REPLACEMENT Install the new heel link and reinstall the pedal. Remember to lubricate the pedal shaft with mineral oil before installing the pedal. Heel Link Pivot Assembly Remove the pedal. Remove the safety panel and side cover. Remove the heel link flange bearing and unhook the extension spring.

  • Page 81: Load Resistor

    PARTS REMOVAL AND REPLACEMENT Remove the leg assembly flange bearing. Remove the jam nut and washer from the leg assembly shaft. Stand by the leg assembly, and pull the leg shaft out from the bearing block. The leg sprocket will drop onto the frame brace. Install the new leg assembly and ensure that the leg assembly shaft key is fully inserted into the key way.

  • Page 82: Pedal Assembly

    PARTS REMOVAL AND REPLACEMENT Remove the drive shaft assembly. Remove the mounting block screws and washers from the bottom of the machine, and remove the mounting blocks. Remove the heel link idler sprockets and the drive chain idler sprockets from the mounting blocks. Attach the drive chain idler sprockets and the heel link idler sprockets to the new mounting blocks.

  • Page 83: Pedal Return Springs

    PARTS REMOVAL AND REPLACEMENT Slide the pedal assembly off the pedal shafts and remove the remaining washers. Install the new pedal assembly in reverse order. PEDAL RETURN SPRINGS Remove the appropriate side cover. Reach between the alternator and the main frame (left side only) to pull up on the spring and remove it from the spring hanger.

  • Page 84: Pulleys

    PARTS REMOVAL AND REPLACEMENT Apply a thin coat of heat sink grease on the aluminum block of the new power control board, and attach the board to the frame. Reconnect all the cables, and reinstall the side cover. PULLEYS Idler Pulley Assembly Remove the side cover.

  • Page 85: Lower Poly-V Pulley

    PARTS REMOVAL AND REPLACEMENT Install the new pulley assembly, and install the belts. Install the upper Poly-V belt and pivot the alternator up or down as necessary to allow ¼” of deflection at the midpoint between the two pulleys (see Figure 20). Reinstall the side cover.

  • Page 86: Step

    PARTS REMOVAL AND REPLACEMENT and remove the rear support bar from the frame. Install the new rear support bar, and have an assistant help you tilt the machine back into place. Reassemble the machine in reverse order. STEP Remove the two bolts and washers from each end of the step. Remove the step.

  • Page 87: Sprockets

    PARTS REMOVAL AND REPLACEMENT WARNING THE SPRING CARTRIDGE IS UNDER HIGH PRESSURE. DO NOT OPEN THE SPRING CARTRIDGE. Install the new spring cartridge, connect the lower heel link chains and have an assistant help you tilt the machine back into place. Tension the heel link turnbuckles and adjust the top edge of the heel link pivot assembly so that it is parallel with the floor (see Figure 27).

  • Page 88: Upper Heel Link Idler Sprockets

    PARTS REMOVAL AND REPLACEMENT Remove the lower Poly-V belt, and remove the snap ring, washers, and lower Poly-V pulley from the drive shaft. WARNING TO REDUCE THE RISK OF EYE INJURY, WEAR EYE PROTECTION WHEN REMOVING SNAP RINGS. Remove the spring from the spring hanger, and disengage the pedal arm spring chain from the sprocket.

  • Page 89: Turnbuckle Assembly Adjustment

    PARTS REMOVAL AND REPLACEMENT Unhook the extension spring from the spring hanger. Remove the jam nut and washer from the heel link assembly shaft. Support the sprocket with chains attached, and remove the heel link assembly from the bearing block. Lower the sprocket and remove the upper heel link chains from the sprocket.

  • Page 90: Grounding Instructions

    GROUNDING INSTRUCTIONS This equipment must be grounded. If it should malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. This equipment has a cord having an equipment-grounding conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances.
  • Page 91 • Consult the dealer or an experienced radio/TV technician for help. WARNING CHANGES OR MODIFICATIONS TO EQUIPMENT NOT ® EXPRESSLY APPROVED BY STAIRMASTER HEALTH & FITNESS PRODUCTS, INC. COULD VOID THE USER'S AUTHORITY TO OPERATE THIS EQUIPMENT. CANADIAN DOC CLASS B COMPLIANCE...

  • Page 92: Important Phone Numbers

    IMPORTANT PHONE NUMBERS If you need assistance, please have both the serial number of your machine and the date of purchase available when you contact the ® appropriate StairMaster Health & Fitness Products, Inc. office listed below. CORPORATE HEADQUARTERS CUSTOMER SERVICE...

  • Page 93: Figure 17: Final Assembly - Left Side

    APPENDIX Figure 17: Final Assembly - Left Side LEG SPROCKET DRIVE CHAIN PN 25946-03 #50, 26.88” PN 25957 DRIVE CHAIN #50, 26.88” PN 25957 STRIDE SENSOR PN 25112 LEG ASSEMBLY FLANGE BEARING POWER CONTROL BOARD PN 25247 PN 25102 LOAD RESISTOR PN 25121 HEEL LINK FLANGE BEARING...

  • Page 94: Figure 18: Final Assembly - Right Side

    APPENDIX Figure 18: Final Assembly - Right Side LEG SPROCKET PN 25946-03 DRIVE CHAIN #50, 26.88” DRIVE CHAIN PN 25957 #50, 26.88” PN 25957 LEG ASSEMBLY FLANGE BEARING HEEL LINK PN 25247 FLANGE BEARING PN 21941 HEEL LINK CHAIN #50, 15.63” PN 25956 DRIVE CHAIN HEEL RETURN SPRING...

  • Page 95: Figure 19: Chain Assemblies

    APPENDIX Figure 19: Chain Assemblies LEFT SIDE 3 DRIVE CHAIN #50, 26.88” 6 X PN 25957 DOUBLE PITCH MASTER LINK 8 X PN 25960 PEDAL RETURN HEEL LINK SPRING SINGLE PITCH CHAIN 2 X PN 21093 MASTER LINK #50, 15.63” 20 X PN 25959 6 X PN 25956 CHAIN LINK...

  • Page 96: Figure 20: Belt Tension

    APPENDIX Figure 20: Belt Tension ALTERNATOR ASSEMBLY W/ BRAKE (PN 22666) UPPER POLY-V BELT PN 21599 INTERMEDIATE POLY-V PULLEY ASSEMBLY LOWER POLY-V BELT PN 25216 PN 21818 IDLER BRACKET ASSY PN 22691 LOWER POLY-V PULLEY PN 21812 Page 87...
  • Page 97 COVER SCREW 26147 2X 25211 DRIVE SHAFT 22703 HEEL LINK SPROCKET THRUST WASHER DRIVE SPROCKET 2X 27065 8X 20197 (20197) 2X 27066 24176 (20197) (20206) (20198) SET SCREW (25949) (27065) 2X 22037 (20197) (25951) (25949) (20198) PULLEY (27066) (20198) 22680 SCREW SNAP RING THRUST...

  • Page 98: Figure 22: Leg Assembly

    APPENDIX Figure 22: Leg Assembly Page 89...

  • Page 99: Figure 23: Heel Link Assembly

    APPENDIX Figure 23: Heel Link Assembly Page 90...
  • Page 100 Leg Link Assy Snap Ring RH PN 25397 (Shown) 2 X PN 20213 LH PN 25396 *Washer Heel Link Assy 2 X PN 21871 RH PN 22719-03 (Shown) LH PN 22717-03 (20213) (21871) Pedal (PN 21817) *Washer PN 23728 Bushing 2 X 20365 (23728) (20365)

  • Page 101: Figure 25: Pedal Assembly

    APPENDIX Figure 25: Pedal Assembly Page 92...

  • Page 102: Figure 26: Master Links

    APPENDIX Figure 26: Master Links DOUBLE PITCH MASTER LINK (PN 25960) DIRECTION OF CHAIN TRAVEL SINGLE PITCH MASTER LINK (PN 25959) DIRECTION OF CHAIN TRAVEL Page 93...

  • Page 103: Figure 27: Heel Link Pivot Adjustment

    APPENDIX Figure 27: Heel Link Pivot Adjustment Page 94...

  • Page 104: Figure 28: Handle Assembly

    APPENDIX Figure 28: Handle Assembly Page 95...

  • Page 105: Figure 29: Limit Switch Assembly

    APPENDIX Figure 29: Limit Switch Assembly BLACK WIRE RED WIRE “BRAKE OFF” SWITCH* MECHANICAL STOPS BRAKE CAM (PN 21840) “BRAKE ON” SWITCH* *PART OF THE LIMIT SWITCH WHITE WIRE ASSEMBLY (PN 27002) GREEN WIRE BRAKE ACTUATOR ARM (PN 22791-05) Page 96...

  • Page 106: Figure 30: Power Control Board "A

    APPENDIX Figure 30: Power Control Board “A” Page 97...

  • Page 107: Figure 31: Led Panel

    APPENDIX Figure 31: LED Panel Page 98...

  • Page 108: Figure 32: Power Control Board "B

    APPENDIX Figure 32: Power Control Board “B” Page 99...

  • Page 109: Figure 33: Alternator Cable

    APPENDIX Figure 33: Alternator Cable Page 100...

  • Page 110: Figure 34: Power Supply

    APPENDIX Figure 34: Power Supply Page 101...

  • Page 111: Figure 35: Load Resistor

    APPENDIX Figure 35: Load Resistor Page 102...

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