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Stairmaster 4G Owner's Manual
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Stairmaster 4G Owner's Manual

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CORE HEALTH & FITNESS
4G
OWNER'S
MANUAL
CONTACT SUPPORT NOW

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Summary of Contents for Stairmaster 4G

  • Page 1 CORE HEALTH & FITNESS OWNER'S MANUAL CONTACT SUPPORT NOW...
  • Page 2 SCREEN VIEWS ..............32 WORKOUT SELECTION KEYS AND PROGRAM DEFINITIONS ....34 MENU MAP ..............35 MAINTENANCE MODE ........................38 REPLACEMENT PARTS ........................54 9-3415-XXXXP0 - 4G ..............54 MAINTENANCE ........................83 TOOLS ..............83 MAINTENANCE SCHEDULE ..............84 SUPPORT & SERVICE ........................85...
  • Page 3 IMPORTANT SAFETY INSTRUCTIONS WARNING! Before using this product, it is essential to read the ENTIRE Owner’s Manual and ALL installation instructions. The Owner’s Manual describes equipment operation and instructs members on how to use correctly and safely. Read all warnings posted on the machine. Health related injuries may result from incorrect or excessive use of exercise equipment.
  • Page 4 This equipment is designed for use in a commercial gymnasium or health club. To ensure the proper use of the 11. Use only replacement components supplied by StairMaster. equipment in a safe manner, all users of the equipment Substitutes are forbidden and will void all warranties.
  • Page 5 PRODUCT SPECIFICATIONS The pages in this section show examples of the warning labels and communication stickers placed on the equipment as part of the manufacturing process. It is critical that owners maintain the integrity and placement of these stickers. If you find any stickers missing or damaged the replacement numbers are shown on the support site.
  • Page 6 050-5711 050-5657 050-5662 LABEL, CAUTION, PINCH, CHAIN KEYPAD, SPEED PLUS MINUS KEYPAD, STOP DRIVE 12 VDC Serial COM 050-5894 050-2051 LABEL, GEN. WARNING, LABEL,BASE PLATE,VLAD COMMERCIAL STAIRCLIMBER, NARROW Page 6...
  • Page 7 PN: 050-5926 REV: A 050-5926 050-5927 ADJUSTMENT STICKER, GAUGE, 4G LABEL, MEASURE POINT, 4G PN: 050-5934 REV: A ADJUST OTHER SIDE EQUALLY 050-5934 LABEL, INSTRUCTION, ADJ. EQUALLY, 4G Page 7...
  • Page 8 PART IDENTIFICATION Fig. 3 4G Features, 19” OpenHub Console Shown Part Part Part Console Leveling Foot UP/DOWN Keypad Shrouds / Housing Stair STOP Keypad Transport Wheel Handrail Main Frame Heart Rate Grips Page 8...
  • Page 9 WHAT’S IN THE BOX Fig. 4 What’s in the Box Description Description 020-8110-XX ASSY, SHROUD, PLASTIC, SIDE, TOP, RADIAL, R, W/ CLIP, 4G 711-4136-XX ASSEM., NECK, W/WIRING & LABELS, 4G 020-8111-XX ASSY, SHROUD, PLASTIC, SIDE, TOP, RADIAL, L, W/ CLIP, 4G 711-4137 ASSEM., FULL HANDRAIL, R, 4G SM...
  • Page 10 HARDWARE CARD Part Number Qty Description 110-3402 SCREW, #8-18, 3/4”, HI-LOW, PHT, PH, CS, BO 110-4180 SCREW, M8x1.25, 65mm, SHC, HK, AS, BEC, NP, GR 10.9 110-4197 SCREW, M8X1.25, 25mm, FLANGED, HEX, ZP, Cl 10.9 110-4229 SCREW, M5x0.8x30, PHM, PH, CS, BZ, DP 110-4329 SCREW, M5x0.8x20, PHM, PH, CS, BZ, DP 110-4364...
  • Page 11 ASSEMBLY PROCEDURE 1. Remove outer cardboard container (not shown). 2. Pry off two wooden supports from the bottom of the pallet then remove. CAUTION: Staples from the pallet may be sharp 3. Remove all packaging material. Set aside hardware card 711-4155 for use.
  • Page 12 Fig. 8 6. Thread the cable bundle up through and out of the top of the mast 711-4135-XX while installing the mast onto the frame. Page 12...
  • Page 13 7. Use a ratchet wrench with a 13mm socket and a 13mm open-ended wrench to secure - DO NOT FULLY TIGHTEN - the mast 711- 4135-XX to the frame using four (4) pieces each of the M8 x 25mm 110-4197 flange bolt 110-4197 and M8 flange nut 110-4364.
  • Page 14 11. Use a 6mm allen key to secure - DO NOT FULLY TIGHTEN - the right side upright handrail 711- 4046-XX to the frame using two (2) of the M8x65mm socket head cap screws 110-4180 and one (1) piece each of the large handrail 110-4180 clamp 020-8146-XX and large threaded handrail clamp 020-...
  • Page 15 14. Use a ratchet wrench with a 13mm socket and a 13mm open-ended wrench to secure - DO NOT FULLY TIGHTEN - the left and right handrails to the mast 711- 4135-XX using (4) pieces each of the M8 x 25mm flange bolt 110- 4197 and M8 flange nut 110-4364.
  • Page 16 17. Connect the heart rate cables 711-4139 and Speed keypad cable 711-4140 coming from the left handrail to the receiving cables coming from the hole in the rear of the mast 711-4135-XX. Heart Rate from 18. Connect the heart rate cables Heart Rate from Right Handrail Left Handrail...
  • Page 17 020-8113-XX 110-4329 21. Use a #2 phillips head screwdriver to secure the top shroud to the frame using two (2) pieces of the M5x20mm pan head machine screw 110-4329. Fig. 17 110-4329 22. Use a #2 phillips head screwdriver to finish securing the top shroud to the frame using two (2) pieces of the M5x20mm pan head machine screw 110-4329.
  • Page 18 110-4329 020-8161-XX 23. Use a #2 phillips head screwdriver to secure the neck cover to the frame using two (2) pieces of the M5x20mm pan head machine screw 110-4329. Fig. 19 020-8162 020-8113-XX 24. Install the mast 711-4135-XX grommet into the top shroud. Fig.
  • Page 19 25. Use a #2 phillips screwdriver to secure the mast 711-4135-XX shroud around the mast 711- 4135-XX and handrails using four (4) pieces of the #8-18, 3/4” pan head machine screw. 110-3402 FRONT MAST SHROUDS REAR MAST SHROUDS Fig. 21 020-8110-XX 110-4229 26.
  • Page 20 Console installation instructions are for the LCD console 700-0538-XX only. For other consoles, refer to their owner’s manual for installation instructions on a G/FC Frame. 28. Unpackage console from box, 020-7923-XX then separate rear shroud from console. 29. Use a #2 phillips screwdriver to 020-7927-XX remove the rear console panel from the rear console shroud, then...
  • Page 21 110-3402 120-3307 31. Use a #2 phillips screwdriver to secure the rear console shroud to the mast 711-4135-XX using eight (8) pieces of the #8-18, 3/4” screw 701-0454-XX 110-3402 and eight washers 120- 3307. 711-4135-XX Fig. 25 CSAFE from Console 32.
  • Page 22 711-4119 701-0357 33. Connect the following cables as 220-0328 shown: Data Cable 411-4119 Heart Rate cable 411-4139 711-4139 Keypad Cable 220-0328 Grounding Cable 701-0357 711-4118 Fig. 27 701-0325-XX 34. Use a #2 phillips screwdriver to secure the front of the console to 110-3402 the rear console shroud using six (6) pieces of the #8-18, 3/4”...
  • Page 23 OPERATION - LCD CONSOLES Fig. 29 10” Non-Touchscreen Shown on 4G Frame Use the keypad controls on the console to select through the screens. After selecting options or immediately after selecting quick start, the active screen will display. Use the buttons to switch between active views.
  • Page 24 CONSOLE KEY FUNCTIONS DISPLAY MEASUREMENTS Time Current total workout time Level Current level, from 1-40 QUICK KEYS Floors Current total floors Calories Accumulated calories burned Cal/Hour Current rate of calorie burn WATTS Current user Watts METS Current User METS Heart Rate Current HR in beats per minute, if available Fig.
  • Page 25 WORKOUT SELECTION KEYS AND PROGRAM DEFINITIONS On the main screen are several choices: Landmark Challenge Choose from 14+ different famous global landmarks to climb Create a Workout Select from a variety of pre-loaded workout options • Goal based programs to enter a Time, Calories or Floors goal •...
  • Page 26 MAINTENANCE MODE LCD CONSOLE Maintenance Mode allows access to service and diagnostic information, as well as provides the ability to adjust certain program default parameters. To enter Maintenance Mode On the numeric keypad, press and hold the keys together. Service Menu will display. Use direction buttons to navigate.
  • Page 27 • MCU SW version Software version for the MCU • MCB SW version Software version for the MCB • Model The product type (4G). • Units The units of measurement (English or Metric). • Language The language that the messages are displayed in.
  • Page 28 MANAGER MODE While in Manager Mode, the following information can be accessed and/or modified: SW Version MCU SW Version: MCB SW Version: 5508B-NoTouch-20230327V4.6 C12A6V31 Language Max Time Default Time Weight Imperial English Save and Exit Exit Fig. 33 • SW version The latest software version loaded in the system.
  • Page 29 DIAGNOSTIC MODE Diagnostic mode is used to verify the functionality of all physical key switches on the product. It is also used to test the functionality of the HR systems. This mode is used to verify the functionality of all physical key switches on the product. It is also used to test the functionality of the HR systems.
  • Page 30 Build A Workout Quick Start Fig. 35 4G Functions CONSOLE & HANDLEBAR FUNCTIONS Enables manual operation using a default weight, SPEED and a default time limit. QUICK START Key NOTE: Default time and weight are adjustable through Maintenance Mode. Press the STOP button to enter pause mode. Workout will be suspended and a STOP Button countdown timer will begin counting down from 2 minutes.
  • Page 31 Unit Button Unit toggle, appears only on home screen Level Adjustment Allows user to increase/decrease program level Workout controls, varies by unit. See the Menu Map in the Console Manual for Main Menu complete details. BLUETOOTH DEVICE PAIRING Bluetooth Device Pairing with Bluetooth Button: Pushing the button puts the console into discover mode.
  • Page 32 SCREEN VIEWS 71.4 7:08 KCAL Total Floors Total Time Floors/Min Floor 28 0:15 Fig. 37 Screen Elements During most workouts, users can select from multiple screen view options by tapping the icons at the bottom of screen. Screens vary by unit, all screens are shown in the Service Manual. •...
  • Page 33 Fan Button Cycles the fan between three settings: High, Low and Off Bluetooth Button is grayed out if no device is connected to the console. Adjustment Allows user to increase/decrease level or steps. Buttons This button has the same function as pressing stop button, puts display into Exit/Back the pause screen.
  • Page 34 & muscular power.   The StairMaster TWENTY curriculum was created specifically to allow exercisers of all fitness levels to reap the benefits of interval training, in a time efficient manner, with a varied approach to keep it fun and engaging!  ...
  • Page 35 MENU MAP For non-touch consoles, use the buttons to switch between active views. Fig. 42 4G Menu Map - Quickstart Page 35...
  • Page 36 For non-touch consoles, use the buttons to switch between active views. Fig. 43 4G Menu Map - Landmark Challenge Page 36...
  • Page 37 For non-touch consoles, use the buttons to switch between active views. For non-touch consoles, use the buttons to switch between active views. Fig. 44 4G Menu Map - Create a Workout Page 37...
  • Page 38 MAINTENANCE MODE Maintenance Mode allows access to service and diagnostic information, as well as provides the ability to adjust certain program default parameters. To enter Maintenance Mode: On the top of the touchscreen, tap the upper left corner, then upper right, then upper left again. Password Screen will display.
  • Page 39 Fig. 48 Maintenance Mode TM (default values shown) MAINTENANCE MODE While in Maintenance Mode, the following information can be accessed and/or modified: • SW versions - The latest software version loaded in the system. • Serial Number - The last five digits of the display serial number. •...
  • Page 40 Fig. 49 Manager Mode (default values shown) MANAGER MODE While in Manager Mode, the following information can be access and/or modified: • SW versions - The latest software version loaded in the system. • Serial Number - The last five digits of the display serial number. •...
  • Page 41 Fig. 50 Network Mode (Ethernet Connected) NETWORK MODE Internet connection information and network settings are shown and changed in this screen. An internet speed of 4mbps for up to 4 machines, then an extra mbps for every additional 4 machines is recommended. Connecting to WIFI Tap Enable RF if not active.
  • Page 42 Tap Scan Wireless Select the correct network then tap Add Network. Fig. 52 Network: Select Network Enter the key in the PSK field then tap Connect Fig. 53 Network: Enter Key Once connected, current connection information appears in the upper right and the active connection is green.
  • Page 43 Fig. 55 Diagnostic Mode DIAGNOSTIC MODE Allows the test of all hard keys, and the telemetry and contact heart rate. Page 43...
  • Page 44 Fig. 56 Usage Statistics USAGE STATISTICS Displays the total number of times a program has been used (programs will differ by equipment type. Page 44...
  • Page 45 Fig. 57 Last Error List LAST ERROR LIST MODE The top row displays the last 5 recorded errors with corresponding data below. Page 45...
  • Page 46 Fig. 58 Calibration & Setup Main Screen CALIBRATION & SETUP The Calibration and Setup screen allows you to calibrate your equipment, update software, customize the user interface and setup the TV. Note: the Calibration and Setup screen is different for each product type.  Speed Calibration Procedure Select Speed Calibration on the Calibration and Setup...
  • Page 47 Incline Calibration Procedure Select Incline Calibration on the Calibration and Setup screen. Press START to begin the calibration. After the Speed Calibration is completed, press EXIT; The Calibration And Setup screen appears. Press to exit and go back to the Home Screen. The Incline Calibration has been completed.
  • Page 48 App Selection Select App Selection on the Calibration and Setup screen. Press an app icon to select or deselect an app. If app is deselected, it will not be available to the user. Once changes are made, press to save and exit or press to cancel and exit.
  • Page 49 Import Images Using the integrated USB port, it is possible to upload custom graphics and images. 1. Upload up to 7 custom images to be used as the background for the home and setup screens 2. Upload a custom logo for the top center of the home screen Fig.
  • Page 50 File Location It is important to place the files on the USB drive in a specific location. If the files are not placed /images/ as shown, the image files will not upload to the console. The total size of all images combined cannot exceed 20 MB.
  • Page 51 Fig. 68 - Tuner Main Screen TUNER Select entertainment input. Selecting Tuner will open up the channel dialog: Channel Scan Procedure Select Channel Scan on the Tuner Configuration screen. Fig. 69 Select Tuner Select the signal type from the Scan Mode option (Both, Analog or Digital).
  • Page 52 Channel Editing Select a channel on the Tuner Configuration screen. Tap ‘edit selected’. In the dialog box that opens, use the ‘visible’ box to add or remove access to the channel from the console, or to rename the channel. Fig. 71 Channel Edit Dialog Channels can be moved from one Capacitive Touch OpenHub console to another with an empty USB flash drive, preventing the need to scan on every unit during an install.
  • Page 53 Fig. 72 Set Top Box Main Screen Set Top Box Select entertainment input. Selecting STB will open up the STB screen. Preset STB’s are selected from the dropdown and by default include the following options (may change without notice): • AMINO •...
  • Page 54 020-8113-XX ASSY, SHROUD, PLASTIC, CENTER, FRONT, W/ CLIP, 4G 020-7705-XX RING, ACCENT, FRONT CAGE, HIIT M & X 020-8114-XX ASSY, SHROUD, PLASTIC, SIDE, BOT, RADIAL, L, W/ CLIP, 4G 020-7890-XX BRACKET, CUP HOLDER, FLEX DECK 020-8119-XX ASSEMBLY, NECK SHROUDS, 4G 020-7908 KEY, 3/16”...
  • Page 55 SPROCKET, 20T, #40, W/ SET SCREWS 110-4329 SCREW, M5x0.8x20, PHM, PH, CS, BZ, DP 711-4116 CHAIN, #40, 0.5” PITCH, OFF SET LINK, STEPS, 4G 110-4353 SCREW, 1/2x13, 2.5 IN, HHC, HE, AS, ZP, PT, GR 10.9 711-4118 ASSY, HARNESS, CSAFE, 4G 110-4360 SCREW, M6x1.0, 45mm, HHC, HE, AS, ZP, FT, GR 10.9...
  • Page 56 CONTACT HEART RATE KITS & REPLACEMENT HARDWARE 711-4108 110-4090 170-0729 721-1325 110-3733 Fig. 74 Page 56...
  • Page 57 CUPHOLDER 020-7431-XX 020-8150-XX 020-7890-XX 110-3608 110-3637 Fig. 75 Page 57...
  • Page 58 EXTERNAL POWER 240-6846 711-4120 711-4145 050-2051 740-7896 140-3588 712-4022 110-4353 120-3030 130-1694 110-4377 220-0272 220-0271 220-0270 Fig. 76 Page 58...
  • Page 59 HANDRAIL BASE & GROMMETS 110-4396 020-8146-XX 110-4180 020-7705-XX 711-4046-XX 020-8147-XX 020-8121 020-8120 Fig. 77 Page 59...
  • Page 60 RESISTOR & ELECTRONICS 020-8082 711-4158 020-8080 110-4226 110-4114 410-0959 711-4121 711-4118 711-4119 Fig. 78 Page 60...
  • Page 61 LOWER DRIVETRAIN 110-4206 130-1973 711-4109 711-4008 130-1699 110-4015 140-3777 130-1839 140-3808 711-4012 711-4115 723-0110 711-4011 140-3827 140-3783 140-3514 110-3548 110-4199 Fig. 79 Page 61...
  • Page 62 MOTOR 110-3504 120-3448 711-4030 711-3770 020-7908 110-3673 110-3970 120-3454 120-3455 731-2346 120-3246 110-4139 110-3973 Fig. 80 Page 62...
  • Page 63 FRONT NECK DETAIL & WIRING, HEART RATE GRIPS 220-0327 110-3404 220-0328 240-6901 050-5662 711-4108 170-0729 050-5657 711-4136-XX 110-4090 110-4364 050-5894 110-4197 711-4140 711-4139 711-4141 711-4139 Fig. 81 Page 63...
  • Page 64 NECK SHROUD DETAIL, NECK TO RAIL, REAR NECK 140-3832 110-4197 110-4364 731-0584 020-8119-XX 110-3402 Fig. 82 Page 64...
  • Page 65 REAR AXLE 740-4552 711-3596 120-3418 711-4116 110-3973 711-4001 110-3373 Fig. 83 Page 65...
  • Page 66 RUNNER PLATES 711-4028 711-4027 711-4026 711-4025 110-4362 120-3387 110-3672 711-4029 Fig. 84 Page 66...
  • Page 67 SAFETY SENSOR & LEVELING FOOT 050-5711 711-4148-XX 110-1823 120-3361 120-3401 110-3773 740-7023 711-4086 110-4229 Fig. 85 Page 67...
  • Page 68 BARRIER SHIELD & HARDWARE 110-3328 020-8102 701-0468 050-5711 701-0470 Fig. 86 Page 68...
  • Page 69 CENTER REAR SHROUD 020-8112-XX 110-4090 110-4229 Fig. 87 Page 69...
  • Page 70 INNER SHROUDS & HARDWARE 020-8097-XX 110-4090 711-4157-XX 711-4085 020-8094-XX 711-4148-XX Fig. 88 Page 70...
  • Page 71 OUTER LEFT SHROUD & GRIP DETAIL 020-8111-XX 110-4229 020-8114-XX 711-4085 020-8130-XX 110-3671 110-3671 711-4151-XX 110-3682 110-4114 120-3536 Fig. 89 Page 71...
  • Page 72 REAR SHROUD & TRANSPORT WHEEL 110-3671 020-8083-XX 110-4229 110-4377 130-1694 120-3030 110-4353 Fig. 90 Page 72...
  • Page 73 OUTER RIGHT SHROUD & GRIP DETAIL 110-4229 020-8109-XX 711-4152-XX 110-3671 020-8110-XX 020-8129-XX 110-4115 120-3536 110-4114 110-3682 Fig. 91 Page 73...
  • Page 74 UPPER SHROUD & NECK SHROUDS 020-8162 020-8119-XX 110-4329 020-8161-XX 110-4090 020-8113-XX 020-8135 110-3671 020-8112-XX Fig. 92 Page 74...
  • Page 75 STEPS 711-4116 711-4004 711-4076 Fig. 93 Page 75...
  • Page 76 TOP AXLE 110-4380 110-3373 120-3387 120-3418 711-4023 711-3596 711-4000 110-3672 110-3673 110-3973 110-4360 Fig. 94 Page 76...
  • Page 77 TRANSMISSION 110-4364 731-0421 711-4012 711-3644 731-2969 110-4218 110-3924 711-3963 560-0069 110-4114 711-4009 Fig. 95 Page 77...
  • Page 78 REPLACABLE WIRING & HARDWARE CARD 711-4141 220-0327 220-0328 711-4140 711-4139 711-4155 711-4121 711-4120 220-0272 711-4119 220-0271 220-0270 711-4118 712-4022 Fig. 96 Page 78...
  • Page 79 700-0537-XX TOUCH CONSOLE EXTERNAL 701-0446-XX 020-7435-XX 701-0454-XX 050-5870 020-8149 731-0584 050-5602 050-5599 240-6846 020-7440-XX 701-0327-XX 701-0328 110-3402 110-3165 701-0330 701-0332 701-0357 110-3629 050-2372 701-0245 701-0329-XX 110-3163 701-0246 701-0115 Fig. 97 Page 79...
  • Page 80 700-0537-XX TOUCH CONSOLE INTERNAL 020-7445 110-3163 701-0027 701-0333 Fig. 98 Page 80...
  • Page 81 700-0538-XX NON-TOUCH CONSOLE EXTERNAL 701-0325-XX 050-5869 050-5872 020-7435-XX 701-0454-XX 050-5602 731-0584 020-8149 050-5599 240-6846 020-7440-XX 701-0327-XX 701-0328 110-3402 110-3165 701-0330 701-0332 701-0357 110-3629 701-0246 050-2372 701-0329-XX 701-0245 110-3163 701-0115 Fig. 99 Page 81...
  • Page 82 700-0538-XX NON-TOUCH CONSOLE INTERNAL 020-7445 110-3163 701-0027 701-0333 Fig. 100 Page 82...
  • Page 83 MAINTENANCE TOOLS Working on this product will require basic and/or sometimes specialty tools based on the type of service that will be performed at any time. To assist, we recommend having the tools listed available when performing maintenance. Tool Metric Allen Key Set Screwdriver Set, Phillips Multi-Meter Metric Open-Ended Wrench Set...
  • Page 84 Inspect the frame for any rust, bubbling, or paint chips during the daily cleaning. The salt in perspiration can damage the unpainted surfaces. Repair the damaged area with a touch-up paint kit purchased from StairMaster® (see Support & Service for order information). CAUTION: Cleaning products may be harmful/irritating to your skin, eyes, etc. Use protective gloves and eye protection.
  • Page 85 SUPPORT & SERVICE CORE CONNECT Core Connect is your portal to all things service! Whether you need to order parts or register your warranty, Core Connect is the most effective way to get what you need fast and keep your facility operating smoothly. OFFERS 24-HOUR SELF SERVICE ACCESS TO: •...
  • Page 86 PART NUMBER 637-8916, REV C All rights reserved. Star Trac, the Star Trac logo and StairMaster are registered trademarks of Core Health & Fitness, LLC. Schwinn and Nautilus are registered trademarks of Nautilus Inc. used under license to Core Health & Fitness LLC. Throwdown is a registered trademark of Throwdown Industries, LLC.

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