Stairmaster FREERUNNER 5600, Owner'S Manual

Page 1: ...FREERUNNER 5600 OWNER S MANUAL...

Page 2: ...ness Products Inc in the UnitedStates and or other countries StairMaster is a Rutledge Capital company P N 22870 A Printed in the United States 2001 StairMaster Health Fitness Products Inc All rights...

Page 3: ...lowing policy has been established Please call our Customer Service Department to receive a Return Materials Authorization RMA number prior to shipment StairMaster Health Fitness Products Inc will inc...

Page 4: ...s and wiring diagrams Throughout this manual the console keypad keystrokes are enclosed in The names of the keys and special console operational modes are shown in capital letters For example your mac...

Page 5: ...5600 ESS CONSOLE 19 The Display Window 19 The Numeric Keypad 20 The Entertainment Keypad 20 The Intensity Level Keys 20 The Stop Key 20 The Workout Statistics 21 The Exercise Program Keypad 22 The Qu...

Page 6: ...roubleshooting Guidelines 39 Basic Electrical Theory 39 The Power Control Board 39 Systematic Electrical Troubleshooting 43 Console Diagnostic Tests 46 Systematic Mechanical Troubleshooting 51 PARTS R...

Page 7: ...s 66 Console 67 Console Handlebar 67 Covers 68 Base Cover 68 Heel Link Pivot Cover 68 Safety Panel 68 Side Cover 68 Drive Shaft Assembly 69 Handle Assembly 69 Handle Knob Assembly 70 Heel Link 70 Heel...

Page 8: ...s VO2max 22 Table 3 Recommended Preventive Maintenance Schedule 38 LIST OF ILLUSTRATIONS Figure 1 Major Parts 3 Figure 2 Shipping Components 5 Figure 3 Tywrap Location 6 Figure 4 Cable Locations 7 Fig...

Page 9: ...Assembly 89 Figure 23 Heel Link Assembly 90 Figure 24 Pedal Mounting 91 Figure 25 Pedal Assembly 92 Figure 26 Master Links 93 Figure 27 Heel Link Pivot Adjustment 94 Figure 28 Handle Assembly 95 Figur...

Page 10: ...G Used to call attention to POTENTIAL hazards that could result in personal injury or loss of life READ ALL INSTRUCTIONS BEFORE USING THE MACHINE To reduce the risk of electrical shock always unplug t...

Page 11: ...cord or plug if it is not working properly if it has been dropped or damaged or dropped in water Contact our Customer Service Department at 1 800 331 3578 for help 10 This equipment is intended for c...

Page 12: ...he 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 sho...

Page 13: ...the StairMaster FreeRunner Elliptical Striding System INTRODUCTION Physical Dimensions Height 64 0 163 cm Depth at base 40 0 102 cm w Console Back Platform 48 0 122 cm Width 52 0 132 cm Weight 485 0...

Page 14: ...re 2 Contact our Customer Service Department at 800 331 3578 for assistance International customers should contact their local distributors Figure 2 Shipping Components INSTALLATION INSTRUCTIONS STEP...

Page 15: ...stener removal tool from the hardware bag to remove the top cover rivets Disconnect the Polar heart rate receiver under the right top cover from the upper Polar heart rate cable see Figure 4 4 Have an...

Page 16: ...ing the mounting screws to the frame Figure 4 Cable Locations 7 Have an assistant help you slide the machine off the shipping pallet and onto the floor Use the transport wheels see Figure 1 to roll th...

Page 17: ...power cable to the DC power connector located on the lower left side see Figure 6 2 Place the power supply on the floor near an AC wall outlet To reduce the hazard of electrical shock place the power...

Page 18: ...supply then plug it back in If the console still does not power up correctly contact our Customer Service Department Refer to the Appendix for the appropriate telephone number 6 The console ready to...

Page 19: ...y deconditioned individuals should be particularly cautious when using the machine for the first time Even though such individuals may not have a history of serious physical problems they may perceive...

Page 20: ...also be disen gaged by pushing the pedals apart forcibly However this is not reccomended as it will cause premature wear on the brake assembly 3 To raise or lower the retractable handles pull the hand...

Page 21: ...do not press ENTER within 60 seconds 5 The console will prompt you to enter your body weight Enter your weight in pounds or kilograms if the console is set to metric Correct entry errors by pressing...

Page 22: ...ole returns to the start screen if you rest longer than the allotted rest period Follow the onscreen prompt to continue your work out after a rest period Cool Down 11 When you are finished with your w...

Page 23: ...ercise If the locked option is selected then the heart rate source signal is locked on the first detected signal during the workout To set a heart rate signal input or to turn off the heart rate optio...

Page 24: ...e heart rate signals This option disables the Constant HR program and the Fitness Test program Error Messages Text line messages are only seen in the Constant Heart Rate and Fitness Test programs due...

Page 25: ...rt rate signal and send it to the receiver The heart symbol on the console pulses to indicate that the console is receiving a valid signal A micropro cessor in the console calculates the heart rate an...

Page 26: ...ove closer to the console Tighten the elastic part of the chest belt Adjust the belt higher or lower on your chest Remoisten the electrodes Test your chest strap with a machine that you know is workin...

Page 27: ...e real time amount of calories burned is continually updated and displayed in the upper right section of the display window Interval Timer The interval timer is displayed below the Time The interval t...

Page 28: ...ication for Fitness Equipment C S A F E port to a connected C S A F E or compatible system If a system is not connected pressing these keys will have no effect Volume Up Down Increases or decreases th...

Page 29: ...el Shows the current intensity level between 1 the easiest and 20 the hardest Watts Displays the exercise intensity in watts 746 watts 1 horsepower METs Gives you the relative energy cost of exercise...

Page 30: ...selected a program the prompts are ENTER BODY WEIGHT type in your body weight in pounds or kilograms if your console is set to metric units ENTER LEVEL 1 20 select your intensity level with level 1 be...

Page 31: ...ated on the profile and any changes in the intensity level will not change the look of the program profile The Speed Intervals Program The Speed Intervals program is a workout with 8 rest intervals an...

Page 32: ...x 70 Choose a different target heart rate be tween 80 and 180 beats per minute at any time during the workout by using the numeric keypad to enter the new target heart rate followed by the ENTER key...

Page 33: ...xercising at a given workload for only a few minutes can involve an insufficient amount of time for many individu als to achieve a true steady state To ensure that a steady state has been achieved the...

Page 34: ...higher than that person s true maximal heart rate then his her estimated VO2 max will be an overestimation of the correct or actual value The final assumption addresses the issue of mechanical efficie...

Page 35: ...ipant from taking part in an exercise test until appropriate medical clearance was obtained PHYSICAL ACTIVITY READINESS QUESTIONNAIRE PAR Q 1 Has your doctor ever said you have a heart condition and r...

Page 36: ...in 5 beats min of each other then that work rate is maintained for an additional minute At the end of the 4th minute the heart rate is compared to the heart rate at the end of the 3rd minute If the he...

Page 37: ...rk Level 6 METs Second Work Level 5 METs Third Work Level 9 METs Fourth Work Level 11 METs Third Work Level 8 METs Fourth Work Level 10 METs FIT TEST PROTOCOL StairMaster CV Products Test Complete Dis...

Page 38: ...0 45 45 41 41 37 37 40 49 48 48 42 42 38 38 35 35 50 59 45 45 39 38 35 35 32 32 60 43 42 35 35 32 32 29 29 WOMEN Age High Good Average Fair Low 20 29 44 44 38 38 35 35 32 32 30 39 41 41 37 37 34 34 31...

Page 39: ...e in this mode pressing LEVEL backs up through the selections pressing ENTER then selects that item If another test level is available at this point the SELECT ENTER process is repeated Pressing 1st o...

Page 40: ...current language Press the SELECT key to scroll through the other options Press ENTER to change the option 5 Adjust the contrast on the LCD screen by pressing LEVEL 3 5 The console will display CONTR...

Page 41: ...4 0 The console will display RUN HOURS XXXXX 2 Display the number of workouts by pressing LEVEL 4 1 The console will display WORKOUTS XXXX 3 Display the total distance covered up to date by pressing L...

Page 42: ...ing After each maintenance period reset the counter 7 1 Reset Service 1 Reset the maintenance hour counter by pressing LEVEL 7 1 The console will dusplay RESET SERVICE Press ENTER The console will dis...

Page 43: ...ator Clips External snap ring pliers Multimeter Allen wrench set sizes 5 64 1 4 Eye protection Torx screwdriver Socket set or nut driver set sizes 1 4 3 4 Combination wrenches sizes 7 16 3 4 MAINTENAN...

Page 44: ...nstructions Cleaning 1 DO NOT USE GLASS CLEANERS OR ANY OTHER HOUSEHOLD CLEANER ON THE CONSOLE Clean the console daily with a water dampened cloth and wipe dry after cleaning 2 Clean the exterior of t...

Page 45: ...chains and around each sprocket with an aerosol synthetic chain lubricant e g PJ 1 3 Thoroughly clean all of the chains every 3 months Use a mild degreaser and a stiff brush to remove dirt and corrosi...

Page 46: ...n e s t c e 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 g a r y r d n a e l C A N n i a h C s e i l b m e s s a e t a c i r b u L r o k e e w h c a E 0 7 y...

Page 47: ...ain cable The power from the main cable turns on the console Inside the console a smaller power control board takes the 12 VDC and redirects 5 VDC back down to the lower power con trol board where it...

Page 48: ...les first If the cables are good then check the console If the console is good then check the power control board LED 3 Alt Off The purpose of this LED is to show if the alternator is being activated...

Page 49: ...t then systematically go through the other possible causes LED 6 Mtr Dir The purpose of this LED is to indicate that the console software is cor rectly controlling the brake motor If you press one of...

Page 50: ...sole is pressed LED 9 will momentarily turn off while the brake cam rotates to the upper limit switch When a workout program is completed or is exited the LED 8 momentarily turns off and the brake mot...

Page 51: ...se a multimeter to verify that the AC line voltage of the wall outlet is between 108 and 130 VAC 208 and 240 VAC if applicable Consult an electrician for further assistance if the voltage is outside t...

Page 52: ...ee diagram below If no voltage is displayed look at LED 1 Vsupply on the lower power board and verify that is lit see page 40 If it is lit disconnect the main cable from the power board and measure ap...

Page 53: ...ing in one direction and a low resistance reading when the multimeter leads are reversed 14 Unplug the load resistor from the power control board Set your multimeter to ohms Insert the multimeter lead...

Page 54: ...t 6 3 Test alternator 6 4 Test continuous brake cycle 6 5 Test brake on off position 6 6 6 9 N A The Display Test During the display test the console screen alternates between all LCD segments turned...

Page 55: ...ce the console if it fails this test The Alternator Test Use this test to verify the alternator field routines of the console You will need to briefly exercise on the machine for this test 1 Press LEV...

Page 56: ...NTER to cycle the motor continuously Verify that the brake cam is triggering the upper and lower limit switches and that the cam is not hitting the mechanical stops see Figure 30 4 Press CLEAR to end...

Page 57: ...the user presses the CLEAR key The second way is as a fatal ERROR which will stop the exercise and return the system to an idle intensity state The console will display the error text and not let the...

Page 58: ...h either the console chest strap or heart rate receiver 3 Verify that the console software has been set up to receive telemetry see the heart rate monitoring section of this manual Note that holding t...

Page 59: ...at 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 False heart beats while the machine is idle are most li...

Page 60: ...hould spin freely four to five revolutions without any clicking or grinding noises Replace the alternator if any noises within the alternator are heard 4 Spin the intermediate and lower Poly V pulleys...

Page 61: ...r signs of wear and corrosion Clean corrosion off the pedal shafts with fine steel wool and replace any worn bushings before reassembling DO NOT SAND THE PEDAL SHAFT 9 Reinstall all parts ensuring pro...

Page 62: ...nator down 5 Remove the upper Poly V belt Inspect the belt for wear and replace the belt if it is cracked cut or otherwise damaged 6 Remove the pivot bolt from the alternator and then remove the alter...

Page 63: ...sembly aside 6 Install the new bearing block assembly reassemble the machine and adjust the top edge of the heel link pivot assembly so that it is parallel with the floor see Figure 27 Bearing Block L...

Page 64: ...Flange Bearing Leg Assembly 1 Remove the appropriate side cover 2 Loosen the two set screws on the flange bearing 3 Remove the two mounting screws and washers and slide the flange bearing assembly off...

Page 65: ...e the upper Poly V belt 2 Push the idler pulley away from the belt see Figure 12 and remove the lower Poly V belt Install the new belt and then reinstall the upper Poly V belt Verify proper tension on...

Page 66: ...he throw on the arm to properly engage disengage the brake see Figure 13 Brake Motor 1 Remove the left side cover 2 Remove the brake actuator arm 3 Remove the brake cam mounting screw and slide the ca...

Page 67: ...flywheel 3 Install the new brake and reassemble the machine 4 Use the brake actuator spring nut and or the lower mounting nut to adjust the throw on the arm to properly engage disengage the brake see...

Page 68: ...The upper main cable splits into two cable assemblies at the bottom of the cable assembly Disconnect the upper main cable from the lower main cable inside the left frame Disconnect the brake cable par...

Page 69: ...m the machine 3 Install the new lower main cable and use a tie wrap to secure the cable away from the leg sprocket 4 Reinstall the cover Limit Switch Cable 1 Turn the power off and remove the left sid...

Page 70: ...n and that the Motor On LED 6 turns off for approxi mately 2 seconds and then turns on and stays on 7 Press the LEVEL key Verify that the Motor Dir LED 6 turns off and stays off and that the Motor On...

Page 71: ...move the left side cover 2 Unplug the power connector from the power control board PARTS REMOVAL AND REPLACEMENT Figure 14 Limit Switch Assembly Brake Off Switch Brake On Switch Trigger Points Motor C...

Page 72: ...d reinstall the side cover CHAINS Upper Heel Link Chains 1 Remove the pedal and the appropriate side cover 2 Remove the power control board left side only 3 Loosen the heel link turnbuckle 4 Remove th...

Page 73: ...the floor see Figure 27 Figure 15 Upper Heel Link Chains Lower Heel Link Chains 1 Remove the base and side covers 2 Rotate the heel link turnbuckle to slacken the chain Note It may be necessary to ro...

Page 74: ...in adapter link 4 Pull the lower chain out from under the drive chain idler sprockets see Figure 21 5 Install the new drive chain assembly Adjust the drive chain turnbuckle so that the chain does not...

Page 75: ...e Do not over tighten over tensioning the turnbuckle will cause the machine to feel rough and cause premature wear of components 7 Reassemble the machine and adjust the top edge of the heel link pivot...

Page 76: ...act heart rate cables if applicable CONSOLE HANDLEBAR 1 Remove the console and the side covers 2 Disconnect the upper main cable from the lower main cable and the lower brake cable 3 Remove the main c...

Page 77: ...cover 2 Install the new cover using the two mounting screws Safety Panel 1 Remove the fasteners from the inside edge of the safety panel 2 Slide the panel out from behind the heel link pivot assembly...

Page 78: ...Disconnect the left and right spring from their respective spring hangars Disengage the step chain from the drive sprockets 5 Remove the drive sprocket thrust washers thrust bearings and spacers from...

Page 79: ...ove the knob pin from the inside of the handle Slide the spring off the knob pin 6 Install the new handle knob assembly on the handle and align the handle yoke groove with the knob pin Ensure that the...

Page 80: ...he chain attached from the pivot assembly shaft 6 Pull the pivot assembly out from the heel link bearing block 7 Install the new pivot assembly and ensure that the pivot shaft key is fully inserted in...

Page 81: ...is parallel with the floor see Figure 27 LOAD RESISTOR 1 Remove the left side cover and unplug the load resistor from the power control board 2 Remove the two mounting screws from the resistor and rem...

Page 82: ...the machine in reverse order and adjust the top edge of the heel link pivot assembly so it is parallel with the floor see Figure 27 PEDAL ASSEMBLY 1 Disengage the brake and push the pedals apart 2 Rem...

Page 83: ...accessibility 3 Detach the spring from the step chain by removing the single pitch master link 4 Reinstall the spring and verify that it is seated in the spring hanger groove POWER CONTROL BOARD 1 Rem...

Page 84: ...4 Remove the snap ring from the pulley and slide the bearings off the shaft 5 Install the new bearings on the idler pulley bracket 6 Reassemble the idler pulley assembly on the frame and ensure that...

Page 85: ...nd washers from the drive shaft loosen the two lower pulley set screws and slide the pulley off the shaft 4 Verify that the drive shaft key is fully inserted into the key way when installing the new p...

Page 86: ...control board and remove the mounting screw from the stride sensor board 3 Install the new board ensuring that the leg sprocket magnet is aligned between the two drilled holes in the stride sensor bo...

Page 87: ...ll of the covers 2 Remove the drive chain assemblies from the drive chain sprockets 3 Remove the drive shaft assembly 4 Remove the heel link chains from the heel link sprockets 5 Remove the mounting b...

Page 88: ...left sprocket with the teeth facing the side cover see Figure 21 7 Reattach the spring and and verify that it is seated in the spring hangar groove Reinstall the side cover Upper Heel Link Idler Spro...

Page 89: ...rom the bearing block 7 Lower the sprocket and remove the upper heel link chains from the sprocket 8 Install the new sprocket and reassemble the machine in reverse order Adjust the top edge of the hee...

Page 90: ...as shown in sketch B if a properly grounded outlet sketch A is not available The temporary adapter should only be used until a properly grounded outlet can be installed by a quali fied electrician Th...

Page 91: ...following measures Reorient or relocate the receiving antenna Increase the separation between the equipment and receiver Connect the equipment to an outlet on a circuit different from that to which th...

Page 92: ...825 800 331 3578 FAX 425 823 9490 FAX 425 814 0601 www stairmaster com E mail customerservice stairmaster com INTERNATIONAL OFFICES AND DISTRIBUTORS INTERNATIONAL DIVISION ASIA PACIFIC HEADQUARTERS 42...

Page 93: ...AIN 50 26 88 PN 25957 MOUNTING BLOCK PN 25932 03 MAIN CHAIN 50 61 88 PN 25958 MAIN CHAIN 50 61 88 PN 25958 HEEL LINK CHAIN 50 15 63 PN 25956 DRIVE CHAIN 50 26 88 PN 25957 HEEL LINK TURNBUCKLE ASSY PN...

Page 94: ...RIVE CHAIN TURNBUCKLE ASSY PN 25936 CHAIN LINK 11 88 PN 25941 05 DRIVE CHAIN 50 26 88 PN 25957 DRIVE SPROCKET ASSY PN 27066 MOUNTING BLOCK PN 25932 03 MAIN CHAIN 50 61 88 PN 25958 MAIN CHAIN 50 61 88...

Page 95: ...88 6 XPN 25957 3 3 SPRINGCHAIN CONNECTOR 2 X PN 25933 4 5 PEDAL RETURN SPRING 2 X PN21093 CHAINLINK 30 25 2 XPN25941 05 7 TURNBUCKLE ASSEMBLY 3X PN 25936 8 CHAIN LINK 15 38 PN25942 05 6 SPRING CARTRID...

Page 96: ...e 20 Belt Tension APPENDIX ALTERNATOR ASSEMBLY W BRAKE PN22666 INTERMEDIATE POLY V PULLEY ASSEMBLY PN25216 IDLER BRACKET ASSY PN22691 LOWER POLY V PULLEY PN21812 UPPER POLY V BELT PN21599 LOWER POLY V...

Page 97: ...065 25951 SCREW 2X 25211 SCREW 4X 25951 25949 MAT 21876 DRIVE CHAIN SPROCKET 4X 25949 MOUNTING BLOCK 2X 25932 THRUST BEARING 4X 20198 SPACER 22781 20197 20198 DRIVE SPROCKET 2X 27066 THRUST WASHER 8X...

Page 98: ...Page 89 Figure 22 Leg Assembly APPENDIX...

Page 99: ...Page 90 Figure 23 Heel Link Assembly APPENDIX...

Page 100: ...Assy RH PN 25397 Shown LH PN 25396 Heel Link Assy RH PN22719 03 Shown LH PN 22717 03 Snap Ring 2 X PN 20213 Washer 2 X PN21871 Pedal PN21817 Washer PN 23728 20213 Bushing 2 X 20365 20365 23728 21871...

Page 101: ...Page 92 APPENDIX Figure 25 Pedal Assembly...

Page 102: ...Page 93 Figure 26 Master Links APPENDIX SINGLE PITCH MASTER LINK PN 25959 DIRECTION OF CHAIN TRAVEL DIRECTION OF CHAIN TRAVEL DOUBLE PITCH MASTER LINK PN 25960...

Page 103: ...Page 94 Figure 27 Heel Link Pivot Adjustment APPENDIX...

Page 104: ...Page 95 Figure 28 Handle Assembly APPENDIX...

Page 105: ...CAM PN21840 BRAKE ACTUATORARM PN22791 05 WHITE WIRE GREENWIRE BRAKE ON SWITCH PART OF THE LIMIT SWITCH ASSEMBLY PN27002 MECHANICALSTOPS BRAKE OFF SWITCH REDWIRE BLACKWIRE Figure 29 Limit Switch Assem...

Page 106: ...Page 97 Figure 30 Power Control Board A APPENDIX...

Page 107: ...Page 98 APPENDIX Figure 31 LED Panel...

Page 108: ...Page 99 APPENDIX Figure 32 Power Control Board B...

Page 109: ...Page 100 APPENDIX Figure 33 Alternator Cable...

Page 110: ...Page 101 APPENDIX Figure 34 Power Supply...

Page 111: ...Page 102 APPENDIX Figure 35 Load Resistor...