Stairmaster StepMill SM5 Technical Manual
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Stairmaster StepMill SM5 Technical Manual

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StairMaster StepMill
®
Technical Manual
Last revised 10/5/15

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Summary of Contents for Stairmaster StepMill SM5

  • Page 1 StairMaster StepMill ® Technical Manual Last revised 10/5/15...

  • Page 2: Important Safety Information

    Important Safety Information The following pages are intended to educate service technicians on the basic maintenance and service actions for the StairMaster StepMills . By following the enclosed instructions and maintenance schedule, you will extend ® the life of your equipment and help ensure it will withstand hours of use in your home/facility.
  • Page 3 Index StairMaster Gauntlet and SM5 - Commercial StepMill Product Details Recommended Tools Preventative Maintenance Major Components Mechanical Adjustments o Alternator Brush Replacement o Alternator Removal / Replacement o Transmission Removal / Replacement o Step Chain Removal / Replacement o Upper / Lower Sprocket Removal / Replacement...

  • Page 4: Technical Specs

    Gauntlet Technical Specs Product Dimensions 58" L x 34" W x 89" H (147cm L x 86cm W x 226cm H) Product Weight 328 lbs (149 kg) Max User Weight 350 lbs (159 kg) Power Requirements Input Voltage 100-240 VAC 50/60 Hz 100 VA Display Three choices of displays.
  • Page 5 Technical Specs Product Dimensions 58" L x 34" W x 89" H (147cm L x 86cm W x 226cm H) Product Weight 343 lbs (156 kg) Max User Weight 350 lbs (159 kg) Power Requirements Input Voltage 100-240 VAC 50/60 Hz 100 VA Display Three choices of displays.
  • Page 6 Tools # Units Tool Suggested Manufacturer Minimum Specifications Multi-meter Various Digital, Continuity, Socket Set, SAE Various 1/4" - 5/8" Socket Set, Metric Various 4mm - 21mm Socket driver Various Open end wrenches, SAE Various 1/4" - 3/4" Open end wrenches, Metric Various 4mm - 17mm Hex Bit Socket Set, SAE...

  • Page 7: Preventative Maintenance

    Clean exterior with soap & water, or diluted household cleaner Parts and Service Regular and scheduled maintenance will prolong the life of your equipment. Only use genuine StairMaster replacement parts. External Power Supply The external power supply is supplied with the unit and plugs into a standard 115 volt, 15 amp outlet, or a 220-240 volt 50Hz, 10 amp outlet.

  • Page 8: Major Components

    Major Components Step Hardware Composite plastic step with a rubber tread built into step top. The step top and kick plate are held together and to the step chains by step hinges, threaded step shafts, nylon spacers, bearings, washers, and bolts. Drive System The upper and lower sprockets are held to the chassis of the machine by pillow block bearings...
  • Page 9 Major Components Drive System Side view of StepMill with covers removed shows the upper sprocket connection to the transmission via drive chain. The transmission is in place to ensure gearing up/down is handled appropriately during a user workout. The upper sprocket has an inner sprocket that connects the drive chain to the transmission sprocket.
  • Page 10 Major Components Resistance System The alternator and transmission connect to the chassis of StepMill as shown. The alternator’s connection pivots allowing the poly-V belt to be tensioned. Tension to 40-54 lbs*inch, or 1/4 of a turn (90 degrees) of deflection. Ensure the belt is not too tight, or damage to the alternator bearings or transmission housing can occur.
  • Page 11 Major Components Power System 12VDC power comes into the lower board at the J2 connection. The console’s J1 connection on the board is where the main data cable plugs in. Wires from the J3 location connect to the appropriate posts on the alternator. When the machine is plugged in and on, the Power and Relay LEDs should be lit.
  • Page 12 Major Components Power System Last revised 10/5/15...

  • Page 13: Mechanical Adjustments

    Mechanical Adjustments 1. Remove alternator belt and inspect for cracks, fraying or any other unusual or excessive wear. 2. Spin alternator pulley to check bearings. 3. Inspect alternator pulley for wear. 4. Check that the transmission pulley set screw is tightened on the flat side of the shaft (check alternator/transmission pulley alignment).

  • Page 14: Alternator Replacement

    Mechanical Adjustments Alternator Brush Replacement 1. Remove user-right side cover 2. Remove brown wire from W3 (FLD BRN) post of alternator. 3. Loosen ¼” bolts on W3 post, or alternator brush assembly 4. Verify brush length and quality. We recommend replacing brushes that are ¼” or less. Alternator Replacement 1.
  • Page 15 Mechanical Adjustments Step Chain replacement 1. Remove side covers. 2. Remove drive chain master link and chain from transmission / upper sprocket. 3. Loosen 9/16” nuts on all 4 pillow blocks from chassis. 4. Count threads on pillow block adjustment screws, and loosen on all pillow block bearings/step chains. 5.
  • Page 16 Consoles 7000 PT / 4400 / 4600 C5 Console • Red LED Readout • Non-replacable overlay • Repair/Exchange through National Gym Supply C40 Console – Blue Faced Overlay • Blue LCD Readout • Console PN#: 055- 0034 • Replacable overlay: PN# - SM27780-001, SM27790, SM27779 •...
  • Page 17 SM916 / SC916 C51/C52 LCD Console • Blue LCD Readout • Console PN#: 003- 3625 • Replacable overlay PN#: SM40468 • Menu map available SM5 / SC5 D1 LCD Console • Blue LCD Readout • Console PN#: 050- 0035 • Replacable overlay PN#: 050-0287 •...
  • Page 18 Gauntlet / Freeclimber D1 LCD Console (Black) • Blue LCD Readout • Console PN#: 050- 0035-35 • Replacable overlay PN#: 050-0287 • USB port for software upload • Menu map available TS-1 / TSE-1 Console (Black) • Touchscreen (TS-1) PN#: 050-0129-35 •...

  • Page 19: Electrical Troubleshooting

    Electrical Troubleshooting Power Trace 050-0232 050-0201 050-0105 050-0236 (ASSY) 050-0161 050-0154 050-0039 SM23545 050-0038 1. No Resistance When Stepping Remove the right side panel to view the three LED’s on the lower PCB board. Begin moving the staircase. If all three of the red LEDs on the relay board are illuminated but there is no resistance, inspect the alternator brushes (SM24557) if worn or the...
  • Page 20 2. No Resistance and No Field Light • Begin moving the staircase. • Staircase freewheels and field LED does not light. • Perform tach test by entering diagnostics. • If there is no tach signal sensed on console. o Check for .6 to .7 volts AC at the W-4 (Tach) terminal of the alternator.
  • Page 21 4. Relay board tests. • Disconnect the main cable from relay board J1 terminal. • With power on, place jumper across GND/BLK and RLY/RED test points. o Relay should light. If not, replace lower PCB board (SM23545). • With power on, place jumper across +/WHT and FLD/BRN test points. o Field should light.
  • Page 22 5. Other Key Points • Remember that the only signal that will prevent the field LED from lighting on the relay board is the tach signal from the blue wire. The console must receive an rpm signal to activate the field current to the alternator that is PWM controlled.
  • Page 23 Last revised 10/5/15...
  • Page 24 Last revised 10/5/15...
  • Page 25 Last revised 10/5/15...
  • Page 26 Alternator / Resistance Testing The colored connections to the alternator are as follows: White-B+ Alternator output voltage Brown Field, Alternator Control Current Black Ground, Alternator return Blue Tachometer, velocity signal back to console Resistance over gravity is performed by the alternator in the StepMill. When the console senses a user with staircase movement, the console should be enabling full field current to the alternator.
  • Page 27 Contact Heart Rate Testing - Gauntlet Make sure there are no loose Contact heart rate is not Check connections in the contact working on the Gauntlet. Connections heart rate system. Perform a Verify that the Continuity heart rate cables Are the cables Check on are connected to connected?
  • Page 28 SM3 – Light Commercial / Residential Technical Specs Product Dimensions 46" L x 29" W x 73" H (117cm x 74cm x 185cm) Product Weight 227 lbs (103 kg) Power Requirements Input Voltage 100-240 VAC 5060 Hz 100 VA Display Backlit LCD Console Workouts Standard console programs...

  • Page 29: Button Selection

    LCD Console • Blue LCD Readout • Console PN#: 723- 0229 • Menu map available Button Selection During console input if any of the following keys are pushed, then the resulting action will occur: QUICK START....Navigate to QUICK START MODE PROGRAMS....Navigate to PROGRAMS MODE ENTER......Confirm the information or value selected UP/DOWN....Increases/decreases value...

  • Page 30: Corporate Headquarters

    CORPORATE HEADQUARTERS Core Health & Fitness 4400 NE 77 Avenue, Suite 300 Vancouver, WA 98662 (888) 678-2476 For further support on StairMaster products, please visit: http://support.stairmaster.com Last revised 10/5/15...

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Stepmill sm3

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