Stairmaster FreeClimber, Service Manual

Page 1: ...GENERAL MAINTENANCE REFERENCE MANUAL 1 800 331 3578 FAX 425 814 0601 INTERNATIONAL 425 823 1825 FAX 425 820 7505 www stairmaster com...

Page 2: ...land WA 98034 1 800 331 3578 FAX 425 814 0601 INTERNATIONAL 425 823 1825 FAX 425 820 7505 www stairmaster com 2002 StairMaster Health Fitness Products StairMaster 4000 PT Crossrobics FreeClimber FreeR...

Page 3: ...on 8000 General Troubleshooting 47 Gravitron 8000 Specific Troubleshooting 48 THE CROSSROBICS EXERCISE SYSTEMS 52 Crossrobics Electrical Troubleshooting 53 Crossrobics Mechanical Troubleshooting 54 Cr...

Page 4: ...Figure 25 Pedal Arm Assembly 58 Figure 26 Right Side View 2650 UE 59 Figure 27 Top View 2650 UE 60 Figure 28 Weight Stack Assembly 61 Figure 29 3300 CE Right Side View 67 Figure 30 3300 CE Left Side V...

Page 5: ...onitor and the cost efficient FreeClimber 4200 PT all designed especially for health clubs The StairMaster FreeClimber and the 4000 PT exercise systems are vertical climbing machines with an independe...

Page 6: ...ap signal sent through the blue wire and sends another signal back down the brown wire to the alternator Alternator Provides the resistance which is varied by the pulsed field signal sent from the con...

Page 7: ...if no resistance is found Don t forget about the possibility of mechanical resistance Worn chains bushings etc may provide some resistance Field Circuit Check VDC at the end of removed brown wire Per...

Page 8: ...ed for an assistant Voltage under load should be between 9 12 VDC on the older style and no less than 12 VDC on the newer style power supply 8 Verify DC voltage on the grey cable pins 4 5 4000 PT pins...

Page 9: ...ower supply board Check AC voltage at TP1 and TP2 on power supply board while stepping minimum 3 5 VAC 6 Reconnect the gray cable at the power supply board and remove console Test AC voltage in pins 2...

Page 10: ...o this bridge the two small holes located at JP1 with a small flat blade screwdriver a small wire or a paper clip When you do this does the console power up YES Adjust the inductive switch closer to t...

Page 11: ...on drive sprocket input one complete revolution The transmission pulley output should turn 19 times 6 Check that the transmission drive sprocket set screw is tight 7 Remove step chains return springs...

Page 12: ...Page 13 BISON TRANSMISSION DETAIL...

Page 13: ...e chain and inspect for frozen links Check that the transmission drive sprocket set screw is tight 6 Spin First Reduction Shaft Assy to check bearings and inspect for excessive wear 7 Remove step chai...

Page 14: ...o t o m W 0 3 l i o n i a h C p e t S n o i t c e n n o C s t n i o P d n a n a e l C e t a c i r b u l 3 y r e v E 0 0 9 r o s h t n o m s r u o h y r d n a e l C g a r i t l u M e s o p r u p e s a...

Page 15: ...Page 16 Figure 1 Final Assembly Left 4600 PT...

Page 16: ...Page 17 Figure 2 Final Assembly Right 4600 PT...

Page 17: ...Page 18 Figure 3 Final Assembly Left 4600 CL...

Page 18: ...Page 19 Figure 4 Final Assembly Right 4600 CL...

Page 19: ...Page 20 Figure 5 Covers 4600 PT CL...

Page 20: ...Page 21 Figure 6 Pedal Arm Assembly First Reduction Shaft Assembly 4600 4400 PT CL 4200 PT...

Page 21: ...Page 22 Figure 7 Drive Shaft Assembly Eccentric Hub Assembly 4600 4400 PT CL 4200 PT...

Page 22: ...Page 23 Figure 8 Final Assembly Left 4400 4200 PT...

Page 23: ...Page 24 Figure 9 Final Assembly Right 4400 4200 PT...

Page 24: ...Page 25 Figure10 Final Assembly Left 4400 CL...

Page 25: ...Page 26 Figure 11 Final Assembly Right 4400 CL...

Page 26: ...Page 27 Figure 12 Covers 4400 PT CL 4200 PT...

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Page 28: ...l climbing machines with a rotating staircase which provides an aerobic workout equivalent to climbing stairs without the impact loads and skeletal trauma common to most aerobic activities Regular use...

Page 29: ...does apply to the 7000 PT 1 Perform the AC tap alternator test 107 enter 1 this tests the blue wire Pin 3 While standing on the stairs the lower left LED should light up on the console indicating a go...

Page 30: ...cable Grey cable pin 2 TP2 brown Field signal from console same as pin 2 of console cable Grey cable pin 3 TP3 blue AC tap signal to console same as pin 3 of console cable connected to alternator AC...

Page 31: ...do not short relay is bad 2 When the relay is de energized LED indicator off TPC and TPB contact should be shorted If not relay is bad F Load Resistor 1 Turn the power off 2 Measure resistance betwee...

Page 32: ...thin itself or from B to normally open post this is normal only while under console control TPA red lead to TPC black lead DVM on ohms OL This tests whether or not the load resistor is shorted to B wh...

Page 33: ...Page 34 4 AC Tap End of blue wire red to TP3 black DVM 1 ohm or less TP3 red to J1 3 black DVM 1 ohm or less...

Page 34: ...wing wires using your voltmeter set on Ohms Disconnect the main cable from the console before testing All tests should read 1 0 Ohms A Disconnect the DC cable Test between Pin 4 of the main cable conn...

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Page 36: ...rocket input one complete revolution The transmission pulley output should turn 19 times 7 Check that the transmission drive sprocket set screw is tight 8 Visually inspect both upper and lower sprocke...

Page 37: ...ive teeth 42 P N 23424 03 Transmission Drive Sprocket teeth 12 P N 23427 Transmission internal ratio 18 75 1 P N 20001 Transmission Pulley diameter 22 P N 20208 Alternator Pulley diameter 18 P N 21157...

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Page 39: ...W A N n i a h C p e t S y l b m e s s A e t a c i r b u L r o y l h t n o M 0 0 3 r e t f a e s u f o s r u o h A N r o t o m W 0 3 l i o d n a n a e l C e t a c i r b u l r o y l r e t r a u Q 0 0 9...

Page 40: ...Page 41 Figure 13 Parts Needing Periodic Lubrication...

Page 41: ...Page 42 Figure 14 Side Cover and Handrail Assemblies...

Page 42: ...Page 43 Figure 15 Poly V Belt Tension...

Page 43: ...Page 44 Figure 16 Drive Chain Assembly...

Page 44: ...Page 45 Figure 17 Step Assembly...

Page 45: ...Page 46 Figure 18 Step Chain and Sprocket Assemblies...

Page 46: ...Page 47 Figure 19 Transmission and Alternator Assemblies...

Page 47: ...Page 48 Figure 20 Wiring Diagram 1...

Page 48: ...Page 49 Figure 21 Wiring Diagram 2...

Page 49: ...Page 50 Figure 22 Wiring Diagram 3...

Page 50: ...es 110 volts AC power to the air compressor and solenoid B Converts 110 volts AC to 12 volts DC minimum for the console C Converts 110 volts AC to 5 volts DC for the transducer 3 GFI Cord Contains a s...

Page 51: ...Page 52 7 Solenoid Release valve that opens at completion of a program and expels air and moisture from the accumulator tank The valve is normally closed...

Page 52: ...orm 2 Program a workout for a 200 lb person at level 9 3 After compressor turns off lift the platform assembly up to full extension 4 Slowly lower platform assembly until it stops on its own 5 The pla...

Page 53: ...er module 4 If voltage is present replace solenoid SYMPTOM PROGRAM GETS HARDER DURING WORKOUT SLOW LEAK 1 Perform leak test on and off platform 2 Use soapy water solution to spray over all components...

Page 54: ...r pyramiding instruction 1 This system has a leak that must be repaired 2 Possible bad keypad in console SYMPTOM WHEN PROGRAMMED FOR HIGHER LEVELS THE PLATFORM WILL NOT RISE AFTER COMPRESSOR SHUTS OFF...

Page 55: ...cal friction Lubricate oilite bushings with 30W oil SYMPTOM AT THE END OF WORKOUT OR WHEN MACHINE IS POWERED UP CONSOLE FLASHES ZEROS 4 TIMES 1 Power module is too far out of zero adjust power module...

Page 56: ...Page 57 ELECTRICAL DETAIL...

Page 57: ...Page 58 SAFETY VALVE...

Page 58: ...e between the Crossrobics 1650 LE conditioning system and other types of exercise is the patented Crossrobics loading system The Crossrobics loading system allows the user independent control of both...

Page 59: ...as a ground Use leads with alligator clips to eliminate the need for an assistant Voltage under load should be between 9 12 VDC on the older style and no less than 12 VDC on the newer style power supp...

Page 60: ...step chains for frozen links 4 2650 UE Align the adapter blocks vertically and verify that the handlebar is parallel to the weight stack Inspect the input chains for twisting near the adapter blocks a...

Page 61: ...n i a h C n i a h C e v i r D e t a c i r b u L r o k e e w h c a E s r u o h 0 7 r e t f a A N r o t o m W 0 3 l i o n a e l c e v o m e R e t a c i r b u l d n a 3 y r e v E 0 0 9 r o s h t n o m s...

Page 62: ...Page 63 Figure 23 Right Side View 1650 LE...

Page 63: ...Page 64 Figure 24 Left Side View 1650 LE...

Page 64: ...Page 65 Figure 25 Pedal Arm Assembly...

Page 65: ...Page 66 Figure 26 Right Side View 2650 UE...

Page 66: ...Page 67 Figure 27 Top View 2650 UE...

Page 67: ...Page 68 Figure 28 Weight Stack Assembly...

Page 68: ...ograms The Stratus uses a variable resistance system to maintain constant power within any given intensity level The resistance decreases as you pedal faster and increases as you pedal slower The vari...

Page 69: ...tch connector while pedaling VAC should increase with RPM 7 Re connect the inductive switch connector to the power control board 8 Measure VAC between test points 10 and 12 of the power control board...

Page 70: ...hain removed to check the pedal bearings and inspect the crank assembly for wear 6 Loosen the J bolt assembly and lower the Alternator Flywheel assembly 7 Verify that the jam nut on the flywheel and t...

Page 71: ...p s n i d n a n a e l C r o k e e w h c a E 0 7 y r e v e r e t f a e s u f o s r u o h r e t a w d n a p a o S d l o h e s u o h d e t u l i d r e n a e l c A N t s o p t a e S t c e p s n i d n a n...

Page 72: ...ock will be considered part of the power control board assembly and will be attached to every control board Heat sink paste thermal compound will be used to help dissipate heat part 13590 7 groove Pol...

Page 73: ...Page 74 Figure 29 3300 CE Right Side View...

Page 74: ...Page 75 Figure 30 3300 CE Left Side View...

Page 75: ...Page 76 Figure 31 3900 RC Right Side View...

Page 76: ...Page 77 Figure 32 3900 RC Left Side View...

Page 77: ...Page 78 Figure 33 3300 CE Seat Adjustment Pin...

Page 78: ...Page 79 Figure 34 3900 RC Seat Assembly...

Page 79: ...Page 80 Figure 35 Drive Chain Assembly...

Page 80: ...Page 81 Figure 36 Intermediate Shaft Assembly...

Page 81: ...Page 82 Figure 37 J Bolt Assembly...

Page 82: ...Page 83 Figure 38 Crank Assembly...

Page 83: ...Page 84 Figure 39 Alternator Assembly...

Page 84: ...tum uses a variable resistance system to maintain constant power within any given intensity level The resis tance decreases as you pedal faster and increases as you pedal slower The variable resistanc...

Page 85: ...red is below 6 0 VDC then the battery is bad 5 Plug the battery connector back into the power control board 6 Test the main cable Remove the four console knobs from the console Gently lift the console...

Page 86: ...the diode to the FLD terminal of the alternator 17 Reconnect the alternator wiring connector to the power control board 18 Test the load resistor Unplug the load resistor from the power control board...

Page 87: ...crank assembly are tight 4 Spin the crank assembly with the belt removed and listen for any clicking or grinding noises The crank should spin freely 4 or 5 revolutions Resume troubleshooting at step...

Page 88: ...t u l i d d l o h e s u o h r e n a e l c t a e S n a e l C k e e w h c a E r e t f a r o 0 7 y r e v e e s u f o s r u o h p a o S r e t a w d e t u l i d d l o h e s u o h r e n a e l c s l a d e P...

Page 89: ...Page 90 Figure 40 Final Assembly Right Side View 3400 CE...

Page 90: ...Page 91 Figure 41 Final Assembly Left Side View 3800 RC...

Page 91: ...Page 92 Figure 42 Seat Post Assembly 3400 CE...

Page 92: ...Page 93 Figure 43 Seat Assembly 3800 RC...

Page 93: ...Page 94 Figure 44 Seat Track Assembly 3800 RC...

Page 94: ...Page 95 Figure 45 Intermediate Poly V Assembly...

Page 95: ...nk Assembly Install with flange to the inside HTD Sprocket Assy 25601 Pedals pair 25642 Bicycle Crank 25643 RH Bearing nut assy 24434 Crank shield 24083 03 Jam nut 24073 LH Bearing nut assy 24435 Main...

Page 96: ...Page 97 Figure 47 Alternator Flywheel Assembly...

Page 97: ...Page 98 Figure 48 Wire Connections...

Page 98: ...Page 99 Figure 49 Power Control Board Plug Ins...

Page 99: ...Alternator P N 2 0 2 0 5 Load Resistor P N 25611 5 O hm 240 W att Positive O utput B W HITE G round T erminal BLACK Field T erminal BR O W N 3400 Upper M ain C able P N 25462 Console to Inline C onnec...

Page 100: ...roup exercise bikes The LeMond RevMaster bike was designed by Greg LeMond Paul Swift and the StairMaster Team Greg LeMond is the first American to win the Tour de France and the only American to ever...

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Page 106: ...cover Use the 4 mm hex key to remove the four mounting screws on the right side cover Use a philips screwdriver to remove the two philips screws on the left side cover Lift the right side cover over t...

Page 107: ...m Rotate the pedals a few revolutions and then tighten the crank arm bolt again to ensure that the crank arm is tightened to 29 5 foot lbs 3 Apply a thin coat of grease on the right bottom bracket sha...

Page 108: ...r Kit 22029 Wheel hardware nut 2 22086 Side Panel Rivets 10 22322 Pedals LH and RH 1 pair 24032 Bearing 15x28 mm RH 1 24387 Bearing 15x35 mm LH 1 24410 Drive Chain 1 24564 Wheel Track Seat Molded 3600...

Page 109: ...al Weight Stack Indicator 1 24437 Handgrips 2 7000 PT Spare Parts Kit 24729 22 00 Part Description Qty Per Kit 20157 Master Link 40 1 20202 Timing Belt Poly V 1 22086 Side Panel Rivets 10 23257 Drive...

Page 110: ...r Spare Parts Kit 1 10778 INSTRUCT BEARING REPLMNT 4000 1 20015 CAP LEVELING ARM 2 20030 RING RETAINING LEVELING ARM 2 20768 CONNECTOR SPRING CHAIN 1 20769 SLEEVE BEARING INSERT 3 21094 PULLEY SPRING...

Page 111: ...ve Sprocket Assy 1 21519 Spring Pulley T2 Units 2 24723 FreeClimber SILVER Spare Parts Kit 1 FreeClimber PLATINUM Spare Parts Kit 675 00 Part Description Qty Per Kit 24724 FreeClimber GOLD Spare Parts...

Page 112: ...minute or 8 75 METs 8 step 40 revolutions of alternator 70 SPM 2 800 RPM of alternator 2 800 RPM 41 25 MPH in automobile 41 25 MPH x 3 650 hours 150 562 5 equivalent miles year VERTICAL FEET CONVERSI...

Page 113: ...re State Building New York 102 985 Eiffel Tower Paris 92 853 Trans America Building San Francisco 81 726 Hoover Dam Nevada 72 630 Gateway Arch St Louis 63 555 Washington Monument DC 55 482 Great Pyram...